Structural component, and method for producing a structural component
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- DEUTSCHES ZENTRUM FÜR LUFT UND RAUMFAHRT E V
- Filing Date
- 2024-08-08
- Publication Date
- 2026-06-17
Smart Images
Figure EP2024072405_13022025_PF_FP_ABST
Abstract
Description
[0001] Structural component and method for producing a structural component
[0002] The present invention relates to a structural component, in particular for use as a lightweight component, and to a method for producing a structural component.
[0003] Structural components are known from the prior art in which an insert is encased in a molten metal, for example, in a die-casting process. By using an insert, the structural properties of the structural component, such as its strength or weight, can be adjusted. Inserts made of aluminum foam structures are used for this purpose. Although these allow for a low weight of the structural component, they are complex and expensive to manufacture. Alternatively, salt cores are also used as inserts, but these have low load-bearing capacity and are heavy and are therefore usually removed from the structural component after the casting process.
[0004] The object of the present invention is to provide a structural component which has a simple and lightweight construction, has high strength and / or rigidity and can be produced cost-effectively.
[0005] This object is achieved according to the invention by a structural component comprising at least one insert body which is at least partially cast or overmolded with a casing, wherein the at least one insert body is formed at least partially from wood and / or a wood material, and wherein the at least one insert body forms a reinforcing and / or stiffening structure.
[0006] Such a structural component can be intended in particular for use as a lightweight component for a wide variety of applications.
[0007] The structural component can be a component with any geometric design.
[0008] For example, the structural component may have an elongated geometry, e.g., in the form of a support, arm, beam, or the like. Likewise, the structural component may have a substantially planar shape. For example, the structural component may be formed as a plate-shaped component.
[0009] In addition, the structural component can have any other geometry, which can be formed in particular by a casting or injection molding process.
[0010] The structural component can, for example, be a profile component.
[0011] Advantageously, the structural component can have shaped areas at least in some areas.
[0012] For example, the design of the structural component can be adapted to the shape of another component.
[0013] Preferably, connecting or fastening devices can be provided on the structural component so that the structural component can be coupled to other components or parts.
[0014] The at least one insert body can have any geometric configuration.
[0015] For example, the insert body may have an elongated geometry to form an elongated structural component, e.g. a support, arm, beam or the like.
[0016] Likewise, the insert body can have a flat geometry in order to form a flat structural component, e.g. a plate-shaped component.
[0017] The insert body can also be designed to be provided only in certain regions of the structural component. For example, depending on its structural properties, the insert body can be arranged in particular in areas of the structural component that are subject to low local loads and / or in areas of the structural component that are subject to high local loads. The insert body forms a reinforcing / stiffening structure in the structural component, particularly depending on its structural properties. Additionally or alternatively, the insert body can form a weight-reducing structure.
[0018] Several insert bodies can also be provided in the structural component.
[0019] By forming at least one insert body at least in sections from a wood and / or wood material, a lighter and more cost-effective insert body can be formed.
[0020] In addition, the wood and / or the wood-based material allows for easy processing, so that the at least one insert body can be easily formed with any desired geometry.
[0021] Particularly preferably, the insert body, in particular the wood and / or the wood material, has a lower density than the casing, in particular the material of the casing.
[0022] Due to the structural properties of wood and / or the wood-based material, the at least one insert body forms a reinforcing / stiffening structure of the structural component.
[0023] The structural component can be designed, for example, as a sandwich component by means of the insert body provided with the sheathing.
[0024] Since wood and / or wood-based materials are cost-effective and sustainable materials, their use can optimize both the manufacturing costs and the ecological footprint of the structural component. Furthermore, the structural component can preferably have fire-retardant properties and / or have a fire-retardant effect on neighboring components.
[0025] A further development of the structural component can provide for the casing of the at least one insert body to be formed by a die-casting process or an injection-molding process. In particular, the casing of the at least one insert body is formed by a die-casting process using a metal material, preferably an aluminum alloy or a magnesium alloy.
[0026] In the injection molding process, the at least one insert body is preferably coated with a plastic material, in particular a thermoplastic or the like.
[0027] Since the casing is formed by a die-casting process or by an injection-molding process, it can be designed to completely enclose the insert body or to enclose it only in certain areas by means of a corresponding design of a casting tool mold.
[0028] In an advantageous development of the structural component, the at least one insert body can be formed at least in sections from solid wood, solid wood, laminated wood, a wood layer composite, a wood fiber composite, a wood chip composite and / or the like.
[0029] Any type of wood suitable for a particular application of the structural component can be used for the insert body.
[0030] Preferably, a structural component with a low weight can be formed by wood with a low density, for example a light wood.
[0031] High-density wood, such as hardwood, can preferably be used to create a structural component with high structural strength and / or rigidity. This can mean both high load-bearing capacity and high compressive strength of the structural component, as well as high temperature resistance.
[0032] Furthermore, the vibration properties, in particular vibration-damping properties, of the structural component can preferably be or have been optimized.
[0033] If the at least one insert body is made of plywood or a wood-layer composite, the structural properties of the insert body can be adjusted depending on the number, thickness, orientation, type of wood, and / or the like of the multiple layers of the plywood or wood-layer composite. In this way, the at least one insert body can be adapted to the loads of a corresponding application area.
[0034] Likewise, the structural properties of the insert body made of a wood fiber composite and / or wood chip composite can be adjustable depending on the size, shape and / or the like of the wood fibers and / or wood chips and / or the adhesive used to form the wood fiber composite and / or wood chip composite in order to adapt the at least one insert body to loads of a corresponding area of use of the structural component.
[0035] A design of the structural component can also provide that at least one cavity is formed in the at least one insert body and / or at least one reinforcing element is provided.
[0036] The at least one insert body can be formed from at least two assembled insert elements. For example, the insert elements can be formed as shell elements, e.g., half-shells, which are assembled to form the at least one insert body before encapsulation or overmolding.
[0037] By assembling the at least one insert body from such shell elements, the cavity can be formed in the at least one insert body in a simple manner.
[0038] By providing the cavity in at least one insert, a particularly lightweight structural component can be formed. Furthermore, the cavity can reduce the amount of material used to manufacture the insert.
[0039] By providing the at least one reinforcing element in the insert body, reinforcement and / or stiffening of the structural element can be achieved.
[0040] Preferably, the at least one reinforcing element can be arranged in the cavity of the insert body. Preferably, the at least one reinforcing element can be arranged in regions of the structural element that are subject to particularly high loads during subsequent use.
[0041] Advantageously, the at least one reinforcing element can also have a lower density than the material of the insert body and / or the sheath.
[0042] The at least one reinforcing element can be formed, for example, as a light wood or hard wood core, a honeycomb structure, a filler body, a foam body and / or the like within the insert element.
[0043] In a further development of the structural component, at least one outer edge region of the at least one insert body can be provided with a functional layer, in particular a wood protection layer, a temperature protection layer, a pyrolysis layer, a corrosion protection layer and / or the like.
[0044] Preferably, the at least one outer edge region of the at least one insert body can be coated, treated, moistened, impregnated and / or the like with the functional layer.
[0045] The outer edge region of the at least one insert body is in particular an outer side of the at least one insert body facing the inner side of the casing.
[0046] Likewise, the at least one insert body can be completely treated, moistened, impregnated and / or the like with a functional liquid forming the functional layer.
[0047] The functional layer can be formed, for example, by a liquid, e.g., water, to adjust the moisture content of at least the edge region of the at least one insert body. This can prevent deterioration of the insert body due to the temperature effects of the casting process.
[0048] An edge region is in particular a volume of the insert body which extends from an outer surface of the insert body, for example at least approximately 2%, preferably at least approximately 5%, and / or less than approximately 15%, preferably less than 10%, of a total material thickness and / or a diameter of the insert body into the interior of the insert body.
[0049] The pyrolysis layer can advantageously be formed during the casting process and the associated thermal exposure of a melt to form the casing. The pyrolysis layer can provide protection for the at least one insert body against mold and / or fungal infestation.
[0050] The corrosion protection layer can advantageously be a reaction layer which, upon contact with the inside of the casing, causes a chemical reaction with the casing material and thus forms corrosion protection on the inside of the casing, i.e. the side of the casing facing the wood.
[0051] A preferred development of the structural component can provide that at least one protective element is provided on the at least one insert body and / or is at least partially introduced into the at least one insert body, and preferably the at least one protective element is arranged corresponding to an inflow region of a casting tool mold and / or a deflection region in the casting tool mold.
[0052] Preferably, the at least one protective element can be formed from a metallic material, advantageously from a material compatible with the melt for forming the sheath.
[0053] Particularly preferably, the at least one protective element can be formed from the same metallic material as the melt for forming the sheath.
[0054] Alternatively, the at least one protective element can also be formed from a temperature-resistant wood and / or wood-based material, for example, from a hardwood, from a wood and / or wood-based material provided with a functional material or a functional layer, for example, a pyrolysis layer, and / or the like. Advantageously, the at least one protective element can be attached to and / or incorporated into the at least one insert body as an inlay on the outside of the insert body.
[0055] By arranging the at least one protective element corresponding to an inflow region of the casting tool mold and / or to a deflection region in the casting tool mold, particularly high temperature effects on the at least one insert body due to the casting process can be reduced and thus impairments / damage to the at least one insert body can be avoided.
[0056] In an advantageous development of the structural component, at least one functional element can be provided on the at least one insert body and / or at least partially incorporated into the at least one insert body.
[0057] Preferably, the at least one functional element provided on the at least one insert body and / or at least partially introduced into the at least one insert body can be exposed to an outer side of the casing.
[0058] In particular, the at least one functional element is a fastening element, a positioning element, a holding element and / or the like.
[0059] Particularly preferably, the at least one functional element can be designed as a passage, a threaded passage, a threaded bore, a sleeve, a threaded sleeve, a pin, a threaded pin, a hook, an eyelet, a projection, a shoulder or the like.
[0060] The at least one functional element can, for example, comprise or be formed from a metallic material, for example aluminum, steel, titanium or an aluminum alloy.
[0061] The at least one functional element is formed, for example, from a material different from the casing or from the same material.
[0062] A further development of the structural component can also provide that the at least one insert body has a plurality of support elements for positioning the insert body in a casting tool mold, wherein the plurality of support elements are formed integrally with the at least one insert body and / or are attached to the at least one insert body.
[0063] In particular, the plurality of support elements are provided for positioning the insert body in a die-casting tool or an injection-molding tool.
[0064] Preferably, the plurality of support elements can be formed from the wood and / or wood material of the at least one insert body.
[0065] In particular, the plurality of support elements can be formed from the wood and / or wood material of the at least one insert body, for example milled out, sawn out or the like.
[0066] Likewise, the plurality of support elements can be formed from the wood and / or wood material of the at least one insert body or from another wood and / or wood material and formed onto the at least one insert body.
[0067] Alternatively, the plurality of support elements can be formed from a metallic material, advantageously from a material compatible with the melt used to form the casing, in particular from the same material, and attached to the at least one insert body. For example, the plurality of support elements can be formed from an aluminum alloy or a magnesium alloy.
[0068] In one embodiment of the structural component, the at least one protective element, the at least one functional element and / or the plurality of support elements can be formed at least partially integrally with the casing after the casting process.
[0069] Preferably, the at least one protective element, the at least one functional element and / or the plurality of support elements can be formed from a material corresponding to the casing, in particular from the same material.
[0070] By forming the at least one protective element, the at least one functional element, and / or the plurality of support elements from a material corresponding to the casing, in particular from the same material, the casting process and the associated temperature exposure can result in at least partial melting of an edge region of the at least one protective element, the at least one functional element, and / or the plurality of support elements by the melt of the casing. After solidification, an integral connection can thus be formed between the casing and the at least one protective element, the at least one functional element, and / or the plurality of support elements.
[0071] A particularly preferred development of the structural component can provide that the casing has at least one section through which the at least one insert body is partially exposed to an outer side.
[0072] In particular, it can be provided that the at least one insert body is partially exposed to the outside of the structural component through an opening in the casing. The at least one insert body can thus be accessible from the outside and / or visible for visual reasons.
[0073] By means of the at least one insert body which is partially exposed to the outside, a connection area for attaching another component can be formed, for example.
[0074] Since the at least one insert body is made of wood and / or the wood material, a simple connection, for example screwing, of the structural component to another component in the region of the exposed section can be made possible.
[0075] In addition, the at least one section exposed to the outside can advantageously provide for the escape of moisture and / or steam from the at least one insert body which has a certain moisture content.
[0076] In particular, the temperature influence during the casting process allows the moisture contained in the at least one insert body to evaporate and escape to the environment via the at least one section of the casing exposed to the outside. In this way, inflation / deformation of the structural component in connection with the casting process can be prevented.
[0077] A further advantageous embodiment of the structural component can also provide that at least one passage extends through the at least one insert body, through which a melt can flow during the casting process to form the casing.
[0078] Due to the at least one passage extending through the at least one insert body, an optimal distribution of the melt in the casting tool mold can be provided during the casting process, in particular the die casting process or injection molding process, in order to form the casing.
[0079] In this way, high manufacturing quality and low scrap of defective structural components can be achieved.
[0080] Preferably, the structural component can be designed as a load-bearing component and / or support component for a device.
[0081] The facility can be any facility in which the structural component preferably has a load-bearing and / or supporting function. Consequently, the use of the structural component is not limited to a specific facility.
[0082] Preferably, the device may be a motor vehicle, a rail vehicle, an aircraft, a machine device, a small appliance device, a supporting structure, a building, a seating structure, a furniture structure and / or the like.
[0083] To achieve the above-mentioned advantages, a method for producing a structural component according to one of the previously described embodiments by a casting process, preferably a die-casting process or an injection-molding process, is also used, in which at least one insert body is positioned in a casting tool mold, in particular a die-casting tool or an injection-molding tool, wherein the at least one insert body is formed at least in sections from wood and / or a wood-based material, the at least one insert body is cast or injection-molded with a molten metal or molten plastic to form an at least regional sheathing of the insert body, and the structural component is demolded from the casting tool mold.
[0084] A further development of the method can also provide that steam, which is formed due to the casting process by a moisture content of the insert body, is discharged from the insert body and / or the casting tool mold.
[0085] In this way, moisture and / or steam can escape from the at least one insert body, which has a certain moisture content, due to the temperature effect during the casting process, so that it can be released into the environment. This can be achieved, for example, by a section in the casing through which the at least one insert body is exposed to the environment.
[0086] Inflation / deformation of the structural component due to the escape of moisture from the at least one insert body can thus be prevented.
[0087] In a further embodiment of the method, at least one outer edge region of the at least one insert body can be provided with a functional layer, in particular a wood protection layer, a temperature protection layer, a pyrolysis layer, a corrosion protection layer and / or the like, before and / or during the encapsulation or overmolding, and / or can be set with a defined wood moisture content, preferably with a wood moisture content between 1% and 30%, particularly preferably between 5% and 15%.
[0088] In particular, an outer side of the at least one insert body facing the inner side of the casing is provided with the functional layer before the casting process. Preferably, the insert body is coated, treated, moistened, impregnated, and / or similarly coated with the functional layer.
[0089] In particular, for such near-surface protection, it can be provided that wood with a moisture content of less than 12%, in particular less than 10%, for example less than 5%, is used as the starting material before the application of the functional layer. Alternatively, it can be provided that the at least one insert body is completely treated, moistened, impregnated, and / or the like with a functional fluid before the casting process.
[0090] After the casting process, the corrosion protection layer can cause a chemical reaction with the material of the casing upon contact with the inside of the casing, through which corrosion protection is formed on the inside of the casing, i.e. the side of the casing facing the wood.
[0091] The pyrolysis layer is advantageously formed during the casting process by the thermal influence of the melt to form the casing. The pyrolysis layer can protect the at least one insert body from mold and / or fungal infestation.
[0092] The defined wood moisture content with which at least the outer edge region of the at least one insert body is set before the casting process preferably corresponds to an average ambient air humidity and / or is preferably between approximately 1% and approximately 30%, in particular between approximately 5% and approximately 15%.
[0093] In particular, at least the outer edge region or only the outer edge region of the at least one insert body is treated with water or water with at least one additive in order to adjust the defined moisture content at least in the edge region or only in the edge region of the at least one insert body. Due to the moisture content, an increased temperature resistance of the at least one insert body to the melt during the casting process can be achieved.
[0094] Further preferred features and / or advantages of the invention are the subject of the following description and the drawings of exemplary embodiments.
[0095] In the figures shows:
[0096] Fig. 1 is a schematic sectional view of a structural component according to an embodiment of the disclosure; Fig. 2 is a schematic sectional view of another structural component;
[0097] Fig. 3 is a schematic side view of an insert body in front of a
[0098] Casting process to form the structural component;
[0099] Fig. 4 is a schematic side view of the insert body in Fig. 3 with a
[0100] Encasing after the casting process to form the structural component;
[0101] Fig. 5 is a schematic side view of the structural component according to a further embodiment according to the disclosure in a longitudinal section;
[0102] Fig. 6 is a schematic sectional view of the structural component according to a further embodiment of the disclosure;
[0103] Fig. 7 is a schematic sectional view of another structural component;
[0104] Fig. 8 is a schematic side view of the structural component according to a further embodiment according to the disclosure in a longitudinal section;
[0105] Fig. 9 is a schematic sectional view of the structural component according to a further embodiment of the disclosure;
[0106] Fig. 10 is a schematic sectional view of the structural component according to a further embodiment of the disclosure;
[0107] Fig. 11 is a schematic sectional view of another structural component;
[0108] Fig. 12 is a schematic side view of the structural component according to a further embodiment according to the disclosure in a longitudinal section; Fig. 13 is a first method step for producing a structural component with
[0109] Functional elements in a longitudinal section according to a further embodiment according to the disclosure;
[0110] Fig. 14 shows a second process step for producing the structural component with
[0111] functional elements;
[0112] Fig. 15 a third process step for producing the structural component with
[0113] functional elements;
[0114] Fig. 16 is a schematic side view of the structural component according to a further embodiment according to the disclosure in a longitudinal section;
[0115] Fig. 17 is a schematic side view of the structural component according to a further embodiment according to the disclosure in a longitudinal section;
[0116] Fig. 18 is a schematic side view of the structural component according to a further embodiment according to the disclosure in a longitudinal section.
[0117] Identical or functionally equivalent elements are provided with the same reference numerals in all figures.
[0118] Fig. 1 and Fig. 2 show schematic cross sections through structural elements designated as a whole by 100 according to embodiments according to the disclosure.
[0119] This structural component 100 is preferably a lightweight component that can be used for a wide variety of applications. The structural component 100 according to Fig.
[0120] 1 is in particular a profile-like structural component 100. The structural component 100 according to Fig. 2 is in particular a plate-shaped structural component 100. In particular, the structural component 100 is designed as a load-bearing component and / or support component that has a load-bearing and / or support function in any device.
[0121] Preferably, the structural component 100 may be a component for a motor vehicle, a rail vehicle, an aircraft, a machine device, a small appliance device, a supporting structure, a building, a seating structure, a furniture structure and / or the like.
[0122] The structural component 100 has a trapezoidal cross-section according to Fig. 1. Likewise, the structural component 100 can have any other cross-section, for example, a rectangular, square, round, oval, or similar cross-section.
[0123] It can also be provided that the cross-section of the structural component 100 changes in its direction of extension.
[0124] The structural component 100 can therefore have any desired geometric configuration, for example an elongated geometry, e.g. in the form of a support, arm, beam or the like, or a substantially planar shape, e.g. as a plate-shaped component.
[0125] Likewise, the structural component 100 can have any other geometry, which can preferably be formed by a casting process or injection molding process.
[0126] For example, one or more shaped regions can be formed on the structural component 100. These can be adapted, for example, to a load on the structural component 100 for reinforcement or stiffening, or to the shape of another component.
[0127] A fastening device 102 can be provided on the structural component 100, by means of which the structural component 100 can be coupled to other components. The structural component 100 is formed by an insert body 104 and a casing 106, which at least partially encloses the insert body 104.
[0128] The casing 106 of the structural component 100 is formed, in particular, by a die-casting process or an injection-molding process. In this process, the insert body 104 is encapsulated or overmolded with a melt in a casting mold (not shown in detail) to form the casing 106.
[0129] In the die-casting process, the casing 106 of the insert body 104 is formed in particular by a metallic material, preferably by an aluminum alloy or a magnesium alloy.
[0130] In the injection molding process, the casing 106 of the insert body 104 is formed in particular by a plastic material, preferably by a thermoplastic plastic or the like.
[0131] By appropriately designing the casting tool mold, the casing 106 can be designed with any defined shape, and the insert body 104 can be completely covered with the casing 106 by the die-casting process or the injection-molding process, or can be covered only in certain regions, as will be described in more detail below.
[0132] The insert body 104 can have a shape adapted to the design of the structural component 100.
[0133] As shown in Fig. 1, the insert body 104 can have a trapezoidal cross-section corresponding to the structural component 100.
[0134] The insert body 104 can also have any other cross-section, in particular a cross-section that deviates from an outer shape of the structural component 100.
[0135] For example, the structural component 100 can also have a rectangular, square, round, oval, flat, plate-shaped, or similar cross-section, or even a cross-section that changes in its direction of extension. Likewise, the insert body 104 can have a cross-section that changes in its direction of extension.
[0136] The insert body 104 can therefore have any geometry that is suitable for being cast or overmolded by a casting or injection process.
[0137] The structural component 100 can also have a plurality of insert bodies 104 that are cast or overmolded by the sheathing 106. The plurality of insert bodies 104 can, for example, be distributed throughout the structural component 100, for example, in areas of low and / or high loads of the structural component 100.
[0138] The insert body 104 is formed at least in sections from wood and / or a wood material.
[0139] In particular, the insert body 104 can be formed at least in sections from solid wood, solid wood, laminated wood, a wood layer composite, a wood fiber composite, a wood chip composite and / or combinations of these.
[0140] Likewise, the insert body 104 can be designed as a hybrid body, which is formed, for example, from the wood and / or wood material and a metallic material, a plastic, a composite material or the like.
[0141] If the insert body 104 is made of wood, this is not limited to a specific type of wood, but rather the type of wood can be selected depending on the use of the structural component 100.
[0142] Preferably, the insert body 104 can be formed from a type of wood with a low density, for example a light wood, in order to form the structural component 100 with a low weight.
[0143] Preferably, the insert body 104 can be formed from a high-density wood species, for example, a hardwood, in order to form the structural component 100 with high structural strength. As a result, the structural component 100 can have high load-bearing capacity and / or compressive strength and / or rigidity. If the insert body 104 is formed from laminated wood or a laminated wood composite, the laminated wood or laminated wood composite can be formed with a defined number, thickness, orientation, wood species, and / or the like of the multiple layers of the laminated wood or laminated wood composite.
[0144] In this way, structural properties of the insert body 104 can be adjusted depending on a use of the structural component 100, for example in order to form a particularly resilient or particularly lightweight structural component 100.
[0145] Likewise, the insert body 104 can be formed from the wood fiber composite and / or wood chip composite, wherein the wood fiber composite and / or wood chip composite can be formed from a defined size, shape, and / or the like of wood fibers and / or wood chips and / or from a defined adhesive. In this way, the structural properties of the insert body 104 made from the wood fiber composite and / or wood chip composite can also be adjusted depending on the use of the structural component 100.
[0146] The insert body 104, in particular at least an outer edge region of the insert body 104, can be provided with a functional layer. This functional layer can preferably be a wood protection layer, a temperature protection layer, a pyrolysis layer, or a corrosion protection layer.
[0147] The outer edge region of the insert body 104 forms an outer side of the insert body 104, which faces an inner side of the casing 106.
[0148] The functional layer can, for example, be applied as a coating to the outer edge region of the insert body 104.
[0149] Likewise, the insert body 104 can be treated, moistened, impregnated, and / or the like with a functional fluid. Furthermore, the insert body 104 can also be completely treated, moistened, and / or impregnated with a functional fluid.
[0150] The functional layer can be formed, for example, by a liquid, e.g. water or water with one or more additives in order to adjust the moisture content of the insert body.
[0151] At least the outer edge region of the insert body 104 can be treated with water or water with at least one additive. In this way, the insert body 104 can be adjusted to a defined wood moisture content. Due to the defined moisture content of the wood and / or wood-based material, an increased temperature resistance of the insert body 104 to the melt during the casting process can be achieved. Damage to the insert body 104 due to the temperature effects of the melt can thus be prevented.
[0152] Preferably, at least the outer edge region of the insert body 104 can be set to a defined wood moisture content between 1% and 30%, particularly preferably between 5% and 15%. Wood moisture content is understood to be the ratio of the water mass contained in the wood to the dry mass of the wood in percent.
[0153] The defined wood moisture content of the insert body 104 can be adjusted depending on a temperature level of the melt for forming the casing 106.
[0154] Preferably, at least the outer edge region of the insert body 104 is set before the casting process with a defined wood moisture content that corresponds to an average ambient air humidity.
[0155] Due to the temperature influence of the melt during the casting process, a pyrolysis layer can form in the outer edge region of the insert body 104. This pyrolysis layer can protect the insert body 104 from mold and / or fungal infestation.
[0156] The corrosion protection layer can be formed as a reaction layer that, upon contact with the material of the casing 106, causes a chemical reaction with the material of the casing 106. This chemical reaction can, after the casting process, form a corrosion protection layer on the inside of the casing 106, i.e., on the side of the casing 106 facing the wood.
[0157] Various embodiments of the structural component 100 according to the disclosure are shown below in Figs. 3 to 18, with the following discussion exclusively on differences between these embodiments and the embodiment of the structural component 100 shown in Figs. 1 and 2. Features not described may therefore correspond to this embodiment. It is understood that features of the various embodiments can be combined with one another as desired.
[0158] Fig. 3 shows a schematic side view of an insert body 104 before a casting process for forming a further embodiment of the structural component 100, and Fig. 4 shows a schematic side view of the insert body 104 in Fig. 3 after the casting process for forming the structural component 100.
[0159] Fig. 3 shows the insert body 104 with a plurality of support elements 108, which are provided for positioning the insert body 104 in a casting tool mold (not shown in detail), in particular a die-casting tool or an injection-molding tool.
[0160] The plurality of support elements 108 are configured to engage the insert body 104 in order to hold it in a defined position within the casting tool mold in order to be able to cast or over-mold it with a melt to form the casing 106.
[0161] The plurality of support elements 108 may be formed from any material, preferably from wood and / or a wood-based material or from a metallic material.
[0162] After the casing 106 has been formed, the support elements 108 are removed from the casting mold during demolding of the structural component 100, leaving exposed sections 110 in which the insert body 104 is exposed to an outer side of the structural component 100, as shown in Fig. 4. These exposed sections 110 ensure that the vapor formed by the moisture content of the insert body 104 due to the temperature effects of the casting process can escape from the insert body 104 to the environment. This can prevent inflation / deformation of the casing 106 due to the formation of vapor.
[0163] Fig. 5 shows a schematic sectional view of the structural component 100 according to a further embodiment according to the disclosure, in which the support elements 108 are configured to remain in the casing 106 of the structural component 100 after the casting process.
[0164] In this embodiment, the plurality of support elements 108 are formed from a material compatible with the melt for forming the sheath 106, preferably from the same material as the sheath 106.
[0165] In particular, the plurality of support elements 108 are formed from a metallic material compatible with a metallic melt for forming the casing 106, preferably from the same metallic material of the casing 106.
[0166] Preferably, the plurality of support elements 108 are formed from an aluminum alloy or a magnesium alloy.
[0167] Likewise, the plurality of support elements 108 may be formed from a plastic material compatible with a plastic melt for forming the sheath 106, preferably from the same plastic material as the sheath 106.
[0168] As shown in Fig. 5, the support elements 108 are formed integrally with the casing 106 after the casting process and therefore remain in the casing 106 of the structural component 100. In this case, subsequent machining of the support elements 108 can be provided following the casting process.
[0169] Fig. 6 and Fig. 7 show schematic sectional views of structural components 100 according to further embodiments of the disclosure. In these embodiments, the support elements 108 for positioning the insert body 104 in the casting mold are formed integrally with the insert body 104.
[0170] In this case, the support elements 108 are consequently formed from the wood and / or wood material of the insert body 104 and remain on the insert body 104 or in the casing 106 after the formation of the casing 106. The support elements 108 are in particular formed, milled, sawn out or the like from the wood and / or wood material of the insert body 104.
[0171] Alternatively, the support elements 108 can also be made of wood and / or the wood material and formed, for example glued, onto the insert body 104.
[0172] After the formation of the casing 106, the insert body 104 can either be exposed in the region of the support elements 108 or the casing 106 can be formed with a smaller wall thickness in the region of the support elements 108 than in the remaining regions of the casing 106.
[0173] Fig. 8 shows a schematic side view of the structural component 100 according to another embodiment of the disclosure in a longitudinal section, in which the insert body 104 is exposed to the outside through a large-area exposed section 110. However, the size of the exposed section 110 can be any size.
[0174] In particular, the exposed portion 110 is formed by the casting process of the casing 106 through a corresponding configuration of the casting mold. An opening is formed in the casing 106, which can have any desired shape and through which the insert body 104 is partially exposed to the outside of the structural component 100.
[0175] The exposed section 110 can preferably be provided for optical reasons and / or to make the insert body 104 accessible from the outside. For example, the insert body 104 exposed to the outside can provide a connection area for attaching or connecting, for example, screwing, gluing, or the like, the structural component 100 to another component in the region of the exposed section 110.
[0176] In addition, this exposed section 110 can also allow moisture and / or steam to escape from the insert body 104, in particular after the casting process.
[0177] Fig. 9 shows a schematic sectional view of the structural component 100 according to another embodiment of the disclosure. This configuration of the structural component 100 provides for a cavity 112 to be formed in the insert body 104.
[0178] The cavity 112 can be formed in such a way that the insert body 104 is composed of two assembled insert elements 114, e.g. half shells, made of wood and / or wood material.
[0179] The provision of the cavity 112 makes it possible to form an insert body 104, by means of which a particularly lightweight structural component 100 can be produced.
[0180] By appropriately designing a wall thickness of the insert elements 114 and / or a corresponding cross section of the insert body 104 formed by the insert elements 114, the structural properties, in particular the strength and / or rigidity, of the insert body 104 and thus of the structural component 100 can also be adjusted.
[0181] A reinforcing element (not shown in detail) can also be arranged in the cavity 112 of the insert body 104. This reinforcing element can reinforce and / or stiffen the insert body 104 and thus the structural element 100.
[0182] For example, it may also be provided that such a reinforcing element is arranged in regions of the insert body 104 in which the structural element 100 is exposed to particularly high loads during subsequent use. Advantageously, the reinforcing element has a lower density than the material of the insert body 104 and / or the casing 106, for example, in the form of a light wood or hardwood core, a honeycomb structure, a filler body, a foam body, and / or the like.
[0183] Fig. 10 and Fig. 11 show schematic sectional views of further structural components 100 according to further embodiments according to the disclosure.
[0184] In these embodiments of the structural component 100, a functional element 116 is provided thereon. This functional element 116 is designed as a fastening element for either attaching the structural component 100 to another component or attaching a component to the structural component 100. For example, the functional element 116 is designed as a threaded passage, a threaded bore, a sleeve or a threaded sleeve, a threaded pin, or the like.
[0185] Several such functional elements 116 can be provided at different positions on the structural component 100.
[0186] The functional element 116 can also be designed as a positioning element and / or a holding element, for example as a projection, a shoulder, a hook, an eyelet or the like.
[0187] The functional element 116 can be attached to the casing 106 by the casting process, in particular by the functional element 116 being formed integrally with the casing 106 by the casting process, or it can be attached to the structural component 100 after the casting process, for example by being welded, screwed, riveted, glued or the like.
[0188] Fig. 12 shows a schematic side view of the structural component 100 according to a further embodiment according to the disclosure in a longitudinal section, in which the functional element 116 is formed as a passage in the structural component 100.
[0189] This functional element 116, designed as a passage, can be configured, for example, for a plug-in element or as a threaded passage for screwing in a threaded element. It is understood that the structural component 100 can have several such functional elements 116 designed as passages.
[0190] The functional element 116 is formed by making an opening in the insert body 104 before the casting process and by allowing the melt to flow into the opening during the casting process to form the casing 106.
[0191] After the casting process, remachining of this opening may be necessary, for example drilling, milling or the like, in order to form the functional element 116 designed as a passage and, if necessary, to provide it with a thread.
[0192] Figs. 13 to 15 show method steps for producing a structural component 100 with several functional elements 116 in a longitudinal section.
[0193] Fig. 13 shows the insert body 104 before the casting process with the several functional elements 116 introduced into the insert body 104.
[0194] The functional elements 116 are, for example, initially semi-finished products, such as bolts or sleeves, which are introduced, in particular inserted, into the insert body 104 and / or into the mold before the casting process. The bolts or sleeves can have any desired configuration; for example, they can protrude from the insert body 104 (as shown in Fig. 13), or they can be provided flush with the insert body 104. The functional elements 116 can preferably be positioned and / or fixed particularly easily by means of the insert body 104.
[0195] Fig. 14 shows the insert body 104 with the functional elements 116 after the casting process with a melt, through which the casing 106 is formed on the insert body 104. The functional elements 116 are fixed by the solidification of the melt and the formation of the casing 106. Fig. 15 shows the finished structural component 100, in which the functional elements 116 are optionally subjected to post-processing after the process step shown in Fig. 14.
[0196] This post-processing may involve the insertion of a bore 118 into the functional elements 116. This bore 118 may either completely penetrate the respective functional element 116 or be inserted into the respective functional element 116 as a blind hole. Alternatively or additionally, a thread may be inserted into the bores 118.
[0197] Furthermore, complex post-processing is conceivable for one or all of the functional elements 116.
[0198] In a supplementary or alternative embodiment, a thread can be formed on an outer periphery of the functional elements 116. This allows a threaded pin to be formed on the structural component 100, for example, for attaching the structural component 100 to another component or for attaching a component to the structural component 100.
[0199] 16 and 17 show further developments of the structural component 100 according to further embodiments according to the disclosure.
[0200] In this embodiment of the structural component 100, a protective element 120 is provided on the insert body 104.
[0201] In particular, this protective element 120 is introduced into the insert body 104 and is preferably provided flush with the outer side of the insert body 104.
[0202] The protective element 120 can be inserted into the insert body 104 as an inlay on the outside thereof or can be attached to it.
[0203] Preferably, the protective element 120 is arranged corresponding to an inflow region of the casting mold, which is indicated by the inflow direction S, and / or a deflection region in the casting mold. Such a deflection region can be formed, for example, in a corner region of the casting mold and / or on an edge of the insert body 104.
[0204] Consequently, the protective element 120 can, for example, also be provided on an edge or an opening in the insert body 104 or form an edge or an opening in the insert body 104.
[0205] The protective element 120 can be arranged both on an upper side of the insert body 104, as shown in Fig. 16, and / or on a side region of the insert body 104, as shown in Fig. 17.
[0206] It is understood that a plurality of protective elements 120 can also be provided on the insert body 104 if, for example, the casting tool mold has a plurality of inflow areas and / or deflection areas for the melt.
[0207] Due to the corresponding arrangement of the protective element 120 to the inflow area and / or deflection area in the casting mold, the high temperature impact on the insert body 104 due to the casting process can be reduced. Impairments and / or damage to the insert body 104 due to the hot melt can thus be avoided.
[0208] Furthermore, the protective element 120 can preferably be used to minimize the damaging effect caused by impacting and deflecting material, in particular flow-related damage.
[0209] The protective element 120 is preferably made of a metallic material, advantageously of a material compatible with the melt for forming the sheath 106, in particular of the same material.
[0210] Likewise, the protective element 120 can be formed from a temperature-resistant wood and / or wood-based material, for example, a hardwood, and / or be provided with a functional material or a functional layer. Fig. 18 shows a schematic side view of the structural component 100 according to another disclosed embodiment in a longitudinal section, in which passages 122 extend through the insert body 104.
[0211] According to Fig. 18, two passages 122 are formed in the insert body 104. However, it is understood that only one passage 122 or more than two passages 122 may be formed in the insert body 122.
[0212] These passages 122 are formed in the insert body 104 so that the melt flows through the passages 122 during the casting process, in particular the die-casting or injection-molding process, to form the casing 106 and can thus be distributed quickly and completely within the casting mold. This enables optimal formation of the casing 106.
[0213] List of reference symbols
[0214] Structural component Fastening device Insert body Sheathing Support element Exposed section Cavity Insert element Functional element Bore
[0215] Protective element passage
Claims
Patent claims 1. Structural component (100), in particular for use as a lightweight component, comprising at least one insert body (104) which is at least partially cast or injection-molded with a casing (106), characterized in that the at least one insert body (104) is formed at least partially from wood and / or a wood-based material, and wherein the at least one insert body (104) forms a reinforcing and / or stiffening structure.
2. Structural component according to claim 1, characterized in that the casing (106) of the at least one insert body (104) is formed by a die-casting process or an injection-molding process.
3. Structural component according to claim 1 or 2, characterized in that the at least one insert body (104) is formed at least in sections from solid wood, solid wood, laminated wood, a wood layer composite, a wood fiber composite, a wood chip composite and / or the like.
4. Structural component according to one of the preceding claims, characterized in that at least one cavity (112) is formed in the at least one insert body (104) and / or at least one reinforcing element is provided.
5. Structural component according to one of the preceding claims, characterized in that at least one outer edge region of the at least one insert body (104) is provided with a functional layer, in particular a wood protection layer, a temperature protection layer, a pyrolysis layer, a corrosion protection layer and / or the like.
6. Structural component according to one of the preceding claims, characterized in that at least one protective element (120) is provided on the at least one insert body (104) and / or is at least partially introduced into the at least one insert body (104), and preferably the at least one protective element (120) corresponding to an inflow area of a Casting tool mold and / or a deflection area in the casting tool mold.
7. Structural component according to one of the preceding claims, characterized in that at least one functional element (116), in particular a fastening element, positioning element, holding element and / or the like, is provided on the at least one insert body (104) and / or is at least partially introduced into the at least one insert body (104), and preferably the at least one functional element (116) is exposed to an outer side of the casing (106).
8. Structural component according to one of the preceding claims, characterized in that the at least one insert body (104) has a plurality of support elements (108) for positioning the insert body (104) in a casting tool mold, wherein the plurality of support elements (108) are formed integrally with the at least one insert body (104) and / or are attached to the at least one insert body (104).
9. Structural component according to one of claims 6 to 8, characterized in that the at least one protective element (120), the at least one functional element (116) and / or the plurality of support elements (108) are formed at least partially integrally with the casing (106) after the casting process.
10. Structural component according to one of the preceding claims, characterized in that the casing (106) has at least one section (110) through which the at least one insert body (104) is partially exposed to an outer side.
11. Structural component according to one of the preceding claims, characterized in that at least one passage (122) extends through the at least one insert body (104), through which a melt can flow during the casting process to form the casing (106).
12. Structural component according to one of the preceding claims, characterized in that the structural component (100) is a supporting component and / or Forms a support component for a device, in particular for a motor vehicle, a rail vehicle, an aircraft, a machine device, a small appliance device, a supporting structure, a building, a seating structure, a furniture structure and / or the like.
13. A method for producing a structural component (100) according to one of claims 1 to 12 by a casting process, preferably a die-casting process or an injection-molding process, comprising the steps: Positioning at least one insert body (104) in a casting tool mold, in particular a die-casting tool or an injection-molding tool, wherein the at least one insert body (104) is formed at least in sections from wood and / or a wood-based material, casting or extrusion-molding the at least one insert body (104) with a molten metal or molten plastic to form an at least regional sheathing (106) of the insert body (104), and demolding the structural component (100) from the casting tool mold.
14. The method according to claim 13, characterized in that steam which is formed due to the casting process by a moisture content of the insert body (104) is removed from the insert body (104) and / or the casting tool mold.
15. The method according to claim 13 or 14, characterized in that at least one outer edge region of the at least one insert body (104) is provided with a functional layer, in particular a wood protection layer, a temperature protection layer, a pyrolysis layer, a corrosion protection layer and / or the like, before and / or during the encapsulation or injection molding, and / or is set with a defined wood moisture content, preferably with a wood moisture content between 1% and 30%, particularly preferably between 5% and 15%.