Method for manufacturing a component, and component manufactured using this method

Abstract

The invention relates to a method for manufacturing a component having a main body which is formed from a component material and has a tubular functional element which is at least in part embedded in the component material, wherein the tubular functional element is first inserted at least in sections into a casting mould, and then component material is introduced in liquid form into the casting mould and flows around at least part of the tubular functional element, and, after the component material has solidified, the component is removed from the casting mould. The problem addressed by the invention is to improve the method known from the prior art for integrating a tubular functional element into a component main body formed by means of a casting process, the improvement being such that the wall thickness of the tubular functional element to be integrated can be kept low in order to meet overall requirements for the weight of the component. Furthermore, the tubular functional element should be able to withstand the casting process despite its reduced wall thickness. In addition, the problem addressed is to improve the function intended for the tubular functional element. The problem is solved by inserting a rod-shaped insert into the tubular functional element before the component material is poured into the casting mould, thereby forming a support structure within the tubular functional element. The invention also relates to a component manufactured using the method.

Description

[0001] Method for producing a component and component produced by this method

[0002] The invention relates to a method for producing a component having a base body formed from a component material and having a tubular functional element embedded at least partially in the component material. The tubular functional element is first inserted at least partially into a casting mold. Subsequently, component material is introduced into the casting mold in liquid form, at least partially surrounding the tubular functional element. After the component material has solidified, the component is removed from the casting mold. Furthermore, the invention relates to a component produced using this method.

[0003] Various types of components are known from the prior art, which comprise at least one base body manufactured from a component material by means of a casting process. Depending on the application of the component, it is also known to integrate a tubular element into the base body manufactured by means of a casting process, which element has a function intended for the respective application.

[0004] Depending on the component material used, the casting process is either a die casting process or an injection molding process. In a die casting process, the casting mold is a die casting mold, whereas in an injection molding process, the casting mold is an injection mold. Metals and metal alloys are typically used as the component material in the die casting process. In the injection molding process, on the other hand, plastics are usually processed at temperatures of up to 400 °C and pressures of up to 700 bar. In the die casting process, significantly higher temperatures of up to 700 °C and higher pressures of up to 2,000 bar are reached when processing the component material. Consequently, die casting molds are designed for higher temperatures and pressures than injection molds.

[0005] For example, DE 10 2015 218 792 A1 discloses a structural component in the form of a chassis subframe for a motor vehicle, in which a tubular functional element serving as a stiffening element is integrated to reduce the weight of the structural component. This structural component is formed by inserting the tubular stiffening element into a mold and then overmolding it with a plastic material. Furthermore, it is known that a metal alloy sheath (e.g., an aluminum alloy) can be used instead of a plastic sheath. The metal alloy sheath is formed by die casting, with molten metal being introduced into the mold.

[0006] The pressures and temperatures prevailing in the mold during both metal die casting and plastic injection molding require a minimum wall thickness for the tubular stiffening element arranged in the mold. This ensures that the tubular stiffening element is not deformed when the molten metal or plastic is introduced. However, the resulting wall thicknesses of the stiffening element can then, in turn, lead to the weight of the entire finished structural component being excessive. Furthermore, the rigidity requirements of the structural component can require such a high wall thickness for the stiffening element that the structural component becomes excessively heavy.

[0007] Another component is known, for example, from DE 10 2021 104 390 A1. This discloses a power electronics component having a plastic injection-molded housing. A pipe is integrated into the plastic injection-molded housing, through which a cooling medium flows during later use of the power electronics component in order to dissipate the waste heat generated by the power electronics component. For weight reasons, the aim is to have the thinnest possible wall for the pipe. However, walls that are too thin can lead to deformation of the pipe due to the temperatures of up to 400 °C and pressures of up to 700 bar that occur during plastic injection molding. In particular, deformation leading to a narrowing of the cross-section of the pipe is disadvantageous because it negatively affects the flow of the coolant.

[0008] Power electronics components are also known which have a base body made of die-cast metal. Here, too, a pipe is integrated into the base body, through which a cooling medium flows during later use of the power electronics component. The pipe is integrated into the casting mold during the formation of the base body and is thus embedded in the liquid metal introduced into the mold. High temperatures and high pressures also typically prevail in metal die casting, so that the integrated pipe is exposed to considerable stress during the formation of the base body. To avoid undesired deformation of the pipe during the formation of the base body, a minimum wall thickness of the pipe must be maintained. However, this minimum wall thickness usually results in a high weight of the pipe and thus in a high weight of the entire power electronics component, which is undesirable.Alternatively, it is known from DE 102017201583 A1 to fill the pipe with a filler during the die-casting process, which is then removed from the pipe after the die-casting process. However, this is complex. Furthermore, residues of the filler can remain in the pipe, which can impair subsequent flow.

[0009] The object of the invention is to improve the prior art method for integrating a tubular functional element into a base body of a component formed by a casting process such that the wall thickness of the tubular functional element to be integrated can be kept low in order to meet the overall weight requirements of the component. Furthermore, the tubular functional element should be durable during casting despite its low wall thickness. Furthermore, the object is to improve the intended function of the tubular functional element.

[0010] This object is achieved by a method having the features of claim 1. Advantageous embodiments can be found in subclaims 2 to 10. Furthermore, the object is achieved by a component having the features of claim 11. Related embodiments can be found in subclaims 12 to 19.

[0011] According to the invention, before forming a base body of a component by means of a casting process, a support structure is constructed in a tubular functional element of the component to be embedded in the base body by inserting a strand-shaped insert into this tubular functional element. For the purposes of the application, a strand-shaped insert is understood to mean a long and narrow element.

[0012] The integrated support structure stiffens the tubular functional element, ensuring that the tubular functional element is supported during the casting process and thus remains dimensionally stable despite the temperatures and pressures encountered during the casting process. Furthermore, the support structure allows the wall thickness of the tubular functional element to be reduced, which can be utilized to reduce the overall weight of the component despite the support structure.

[0013] Since the strand-shaped insert can remain in the tubular functional element after the component's base body has been manufactured, the support structure can also provide additional functions beyond the casting process. For example, if the tubular functional element serves to stiffen a component designed as a structural component, the support structure can improve this stiffening. For example, if the tubular functional element serves to conduct a temperature control medium in a component designed as a temperature control device, the support structure can improve the heat exchange between the tubular functional element and the temperature control medium.

[0014] By inserting a strand-shaped insert into the tubular functional element, existing production processes for the manufacture of cast components with tubular functional elements can also be easily expanded.

[0015] The strand-shaped insert lying loosely within the tubular functional element is also advantageous if the tubular functional element, with the insert arranged inside, is bent prior to forming the base body. The loose fit of the insert in the tubular functional element allows for displacement of the insert relative to the inner wall of the tubular functional element during bending, so that the support structure formed between the insert and the tubular functional element does not distort during bending, thus preserving its supporting function.

[0016] “Loose fit” in the sense of the invention means that the insert part is arranged in the tubular functional element without the insert part and the tubular functional element being integrally connected to one another.

[0017] An embodiment of the invention is explained below with reference to the drawings. They show:

[0018] Fig. 1 spatial representation of an embodiment of a component according to the invention designed as a structural component

[0019] Fig. 2 a partially sectioned view of Fig. 1

[0020] Fig. 3 is a sectional view of the structural component 1 according to Fig. 1 along the section line AA'

[0021] Fig. 4 a cross-section of the support structure 2 according to Fig. 3

[0022] Fig. 5 a cross-section of an alternative embodiment of the support structure 2

[0023] Fig. 6 shows an embodiment of the component according to the invention designed as a temperature control device with base body and pipeline

[0024] Fig. 7a is a partially sectioned view of the pipeline with the support structure arranged inside the pipe according to Fig. 6

[0025] Fig. 7b is a further partially sectioned view of the pipeline with the support structure arranged inside the pipe according to Fig. 6. Fig. 7c is a cross-section perpendicular to the flow direction of the pipeline through the pipeline with support structure according to Fig. 7a along section AA'.

[0026] Fig. 7d a sectional view of Fig. 6 along section BB'

[0027] Fig. 8a a partially sectioned view of the pipeline with a further embodiment of the support structure arranged inside the pipe

[0028] Fig. 8b a cross-section perpendicular to the flow direction of the pipeline through the pipeline with support structure according to Fig. 8a along section AA' according to Fig. 6

[0029] Fig. 8c a sectional view of Fig. 6 along section BB' with the support structure according to Fig. 8a

[0030] Fig. 8d is a sectional view of Fig. 6 along section CC' with the support structure according to Fig. 8a

[0031] Fig. 9a a partially sectioned view of the pipeline with a further embodiment of the support structure arranged inside the pipe

[0032] Fig. 9b a cross-section perpendicular to the flow direction of the pipeline through the pipeline with support structure according to Fig. 9a along section AA' according to Fig. 6

[0033] Fig. 9c a sectional view of Fig. 6 along section BB' with the support structure according to Fig. 9a

[0034] Fig. 9d is a sectional view of Fig. 6 along section CC' with the support structure according to Fig. 9a

[0035] Fig. 1 shows a spatial representation of an embodiment of a component 1 according to the invention designed as a structural component. Structural components are used, for example, as load-bearing components in vehicles. The illustrated embodiment shows a component 1 designed as a structural component in the form of a longitudinal member of an axle support of a vehicle, without the invention being limited to such structural components 1.

[0036] The structural component 1 comprises a base body 1a, which is formed from a component material by means of a casting process. A tubular functional element 3 is embedded at least in sections in the base body 1a, which here performs a stiffening function. Furthermore, a strand-shaped insert 5 is arranged in the tubular functional element 3.

[0037] Fig. 2 shows a partially sectioned view of Fig. 1, so that part of the tubular functional element 3 embedded in the base body 1a with the strand-shaped insert 5 arranged therein is visible. Fig. 3 shows a sectional view of the structural component 1 according to Fig. 1 along the section line AA'. The base body 1a and the support structure 2 with the tubular functional element 3 and the insert 5 are visible. The support structure 2 has struts 6 in a cross-section perpendicular to the longitudinal direction of the tubular functional element 3, which struts each support opposite sections 3a, 3b of the inner wall of the tubular functional element 3.

[0038] In the embodiment shown, the struts 6 are arranged in the cross-section perpendicular to the longitudinal direction of the tubular functional element 3, radially to the central longitudinal axis 7 of the tubular functional element 3. The central longitudinal axis 7 of the tubular functional element 3 refers to the axis that runs in the middle of the tube along the longitudinal direction of the tubular functional element 3. One end of each of these struts 6 rests loosely against the inner wall of the tubular functional element 3. The other ends of the struts 6 face each other and are connected to each other.

[0039] In the cross-section perpendicular to the longitudinal direction of the tubular functional element 3, an envelope of an outer contour of the insert part rests, at least in sections, against an envelope of the inner contour of the tubular functional element. The ends of the struts 6, which rest loosely against the inner wall of the tubular functional element 3, rest on the envelope of the outer contour of the insert part, and the inner wall of the tubular functional element 3 forms the envelope of the inner contour of the tubular functional element 3.

[0040] The ends of the struts 6 facing the inner wall of the tubular functional element 3 have support surfaces 6a that rest against the inner wall of the tubular functional element 3. However, these support surfaces 6a are not mandatory.

[0041] The mutually facing ends of the struts 6 are connected to each other via a tubular channel element 4 arranged along the longitudinal direction of the tubular functional element 3. However, this is not mandatory. The mutually facing ends of the struts 6 can also be connected directly to each other, for example.

[0042] Fig. 4 shows a cross-section of the support structure 2 according to Fig. 3 with the tubular functional element 3 and the strand-shaped insert 5. Fig. 5 shows a cross-section of an alternative embodiment of the support structure 2 formed between the tubular functional element 3 and the strand-shaped insert 5. Here too, the struts 6 are arranged in the cross-section perpendicular to the longitudinal direction of the tubular functional element 3 and radially to the central longitudinal axis of the tubular functional element 3. However, one end of each of these struts 6 is fastened to the inner wall of the tubular functional element 3. The other ends of the struts 6 face one another and are spaced apart from one another. The strand-shaped insert 5 is designed as a tubular element. The mutually facing ends of the struts 6 rest on an outer surface (outer circumferential surface) of the tubular element.Alternatively, the strand-shaped insert 5 can also be designed as a rod element, in which case the mutually facing ends of the struts 6 rest on an outer surface (outer surface) of the rod element. Even with such a design of the support structure 2, opposing sections 3a, 3b of the inner wall of the tubular functional element 3 are supported.

[0043] In the cross-section perpendicular to the longitudinal direction of the tubular functional element 3, an envelope of an outer contour of the insert part rests, at least in sections, against an envelope of the inner contour of the tubular functional element. The ends of the struts 6, which rest loosely on the outer surface of the rod or tubular element, rest on the envelope of the inner contour of the tubular functional element 3, and the outer surface of the rod or tubular element forms the envelope of the outer contour of the insert part.

[0044] Depending on the design of the structural component 1, the component material can be a plastic, a metal, or a metal alloy. For example, the metal alloy can be an aluminum die-casting alloy, without the invention being limited thereto. Likewise, the component material can also be a plastic with or without a filler. For example, the filler can contain fiber materials that increase the rigidity of the plastic.

[0045] Depending on the design of the structural component 1, the tubular functional element 3 is designed as a metal tube. For example, the metal tube can be an aluminum tube. However, the invention is not limited to this. If the component material is a plastic, the tubular functional element 3 can also be made of plastic, for example. Analogously, the insert 5 is also made of a metal, a metal alloy, or a plastic. The method according to the invention for producing a structural component 1 with a base body 1a, which is formed from a component material and has a tubular functional element 3 embedded at least in sections in the base body 1a, is described in more detail below. Here, the tubular functional element 3 is inserted at least in sections into a casting mold.Subsequently, component material in liquid form is introduced into the casting mold, wherein the liquid component material then at least partially flows around the tubular functional element 3. After the component material has solidified, the structural component 1 is removed from the casting mold. According to the invention, a support structure 2 is formed in the tubular functional element 3 before the liquid component material is introduced into the casting mold. To form the support structure 2, a strand-shaped insert 5 is inserted into the tubular functional element 3 before, during or after the insertion of the tubular functional element 3 into the casting mold, at least along a section of the tubular functional element 3 arranged in the casting mold. The tubular functional element 3 with the inserted insert 5 then forms the support structure 2, wherein this support structure 2 has the above-mentionedStruts 6, which support opposing sections 3a, 3b of the inner wall of the tubular functional element 3. After the component material has solidified and is removed from the casting mold, the strand-shaped insert 5 remains in the tubular functional element 3 when the structural component 1 is used.

[0046] In one embodiment of the method, the support structure 2 is designed such that the struts 6, as part of the tubular functional element 3, are arranged in the cross-section perpendicular to the longitudinal direction of the tubular functional element 3 and radially to the central longitudinal axis of the tubular functional element 3, and one end of each of these struts 6 is fastened to the inner wall of the tubular functional element 3. The other ends of the struts 6 face each other and are spaced apart from each other. The strand-shaped insert 5 is a rod or tube element and is inserted between the mutually facing ends of the struts 6. The insert 5 and the length of the struts are dimensioned such that the mutually facing ends of the struts 6 rest on an outer surface of the rod or tube element.

[0047] In an alternative embodiment of the method, the support structure 2 is designed such that the struts 6, as part of the strand-shaped insert 5, are arranged in the cross-section perpendicular to the longitudinal direction of the tubular functional element 3 and radially to the central longitudinal axis of the tubular functional element 3, and one end of each of these struts 6 rests loosely on the inner wall of the tubular functional element 3. The other ends of the struts face each other and are connected to each other. By inserting the strand-shaped insert 5 into the tubular functional element 3, with appropriate dimensioning of the length of the struts 6, the ends of the struts 6 rest against the inner wall of the tubular functional element 3 is achieved.

[0048] In order to achieve a bent design of the structural component 1 (as shown, for example, in Fig. 1), the tubular functional element 3 with the inner insert 5 is bent using a bending method known from the prior art before being inserted into the casting mold.

[0049] Fig. 6 shows a component 1 manufactured using the method according to the invention and designed as a temperature control device, wherein this temperature control device 1 has a base body 1a and a tubular functional element 3 embedded in the base body 1a. This tubular functional element 3 is provided here for the passage of a temperature control medium during use of the temperature control device 1. The base body material consists of a highly thermally conductive metal (e.g., aluminum or magnesium) or a metal alloy (e.g., an aluminum alloy), or even a plastic provided with a filler. The filler preferably serves to improve the thermal conductivity of the plastic.

[0050] Temperature control devices are used, for example, in vehicles, in charging stations for electromobility or in static energy storage systems, although the invention is not limited to these.

[0051] To manufacture the temperature control device 1, a support structure 2 (Fig. 7a) is first constructed in the pipeline 3. The support structure 2 is constructed by loosely inserting a strand-like insert 5 into the pipeline. This strand-like insert 5 has struts 6 (Fig. 7c) that support opposing sections 3a, 3b (Fig. 7c) of the inner wall of the pipeline 3 against each other in a cross-section perpendicular to the flow direction of the pipeline 3. Furthermore, channels 7 (Fig. 7c) through which a temperature control medium can flow are formed between the struts 6 along the pipeline 3.

[0052] Depending on the design of the temperature control device 1, the tubular functional element 3 is designed as a metal tube. For example, the metal tube can be an aluminum tube. However, the invention is not limited to this. If the component material is a plastic, the tubular functional element 3 can also be made of plastic, for example. Analogously, the insert 5 is also made of a metal, a metal alloy, or a plastic. Depending on the application, the pipeline with the support structure integrated at least in sections can be bent so that, for example, as shown in Fig. 6, the tube ends 3c, 3d point in the same direction.

[0053] After bending the pipe 3, it is inserted into the casting mold, at least in sections. The casting mold, however, is not shown. The inner contour of the casting mold is designed to be congruent with the outer contour of the future base body 1a of the component. The casting mold is typically constructed in several parts so that it can be opened again at the end of the process to remove the base body 1a from the casting mold. To produce the illustrated embodiment of the temperature control device 1, the pipe 3 is inserted into the casting mold such that the pipe ends 3a, 3b of the pipe 3 protrude from the casting mold.

[0054] After the pipeline 3 has been inserted into the casting mold and, if necessary, the casting mold has been sealed, base material is introduced into the casting mold using a casting process. The base material flows at least partially around the pipeline 3. The support structure 4 supports the opposing sections 3c, 3d of the inner wall of the pipeline 3 during the introduction of the casting, thus preventing compression of the pipeline 3 due to the temperatures and pressure conditions prevailing during casting. After the base material has been introduced, it solidifies in the casting mold, simulating the inner contour of the casting mold. In an optional embodiment, a cooling medium is passed through the pipeline 3 with the support structure 4 during the die casting of the base material into the casting mold and / or during the solidification of the base material.

[0055] After solidification and, if necessary, further cooling of the base body material, the tempering device 1 is removed from the casting mold and is then present as shown in Fig. 6. The support structure 4 remains in the pipeline 3 after the removal of the tempering device 1 from the casting mold and during subsequent operation of the tempering device 1. Flow through the pipeline 3 with tempering medium is ensured by the channels 5 provided along the pipeline 3 in the support structure 4.

[0056] The pipe ends 3c, 3d are intended for later connection to a coolant circuit, with the pipe ends 3c, 3d having recesses for a tight connection to the coolant circuit. These recesses can be formed before the pipe is inserted into the mold, after the pipe 3 is inserted into the mold, or even after the temperature control device 1 is removed from the mold. Various approaches are proposed for integrating the support structure.

[0057] Fig. 7a and Fig. 7b show the pipeline 3 with the insert 5 arranged inside the pipe according to Fig. 6, although the pipeline 3 is only partially shown in each case, thus revealing the view of the support structure 2 or the insert 5. In the illustrated embodiment, the support structure 2 lies along the entire section of the pipeline 3 arranged in the casting mold. This is not mandatory, however. Depending on the application, a section-by-section insertion of the insert 5 along the section of the pipeline 3 arranged in the casting mold may also be sufficient.

[0058] Furthermore, the method is not limited (as shown) to curved pipes 3. Straight pipes 3 can also be inserted into the casting mold. Since bending the pipe 3 is not necessary in this case, the support structure can also be inserted into the pipe during or after the pipe is inserted into the casting mold.

[0059] Fig. 7c shows a cross-section through the pipeline 3, perpendicular to the direction of flow through the pipeline 3, with the insert 5 according to Fig. 7a along section AA'. In the embodiment shown, the struts 6 are arranged radially to the axis of symmetry of the pipeline 3, relative to the cross-section perpendicular to the direction of flow through the pipeline 3. The longitudinal axes 8 of the struts 6 intersect at the axis of symmetry 9 of the pipeline 3. This insert 5 is inserted into the pipeline 3. Ends of the struts 6 facing the inner wall of the pipeline then rest loosely on the inner wall of the pipeline 3. Ends of the struts 6 facing away from the inner wall of the pipeline 3 face each other and are firmly connected to each other. In the embodiment shown, the mutually facing ends of the struts 6 are connected to each other via a channel element 4 arranged along the pipeline 3.In the cross-section shown, the channel element can be seen as an annular section of the support structure 2. In addition to the channels 7 formed between the struts 6, the channel element 4 also forms a channel through which the temperature control medium can flow. However, connecting the facing ends of the struts 4a via a channel element is not mandatory.

[0060] In the cross-section perpendicular to the longitudinal direction of the tubular functional element 3, an envelope of an outer contour of the insert part rests, at least in sections, against an envelope of the inner contour of the tubular functional element. The ends of the struts 6, which rest loosely against the inner wall of the tubular functional element 3, rest on the envelope of the outer contour of the insert part, and the inner wall of the tubular functional element 3 forms the envelope of the inner contour of the tubular functional element 3.

[0061] The invention is not limited to the illustrated embodiment of the support structure 2 or the insert

[0062] 5 with six struts 6. For example, the insert 5 can also have more or fewer struts 6. Likewise, the ratio of the diameter of the annular section of the insert 5 to the diameter of the pipe cross-section can be smaller or larger than in the illustrated embodiment. It is also not mandatory that the ends of the struts 6 facing away from the inner wall of the pipeline 3 be connected to one another via an annular section of the insert 5. Likewise, the struts 6 can also be designed to be continuous.

[0063] A further embodiment of the support structure 2 is shown in Fig. 8a to Fig. 8c. Similar to the embodiment according to Fig. 7a to Fig. 7d, the support structure 2 is formed by a strand-shaped insert 5, which in cross-section has struts 6 arranged perpendicular to the flow direction of the pipeline 3 and radially to the axis of symmetry of the pipeline 3, wherein this insert 5 is inserted into the pipeline 3 before, during or after the insertion of the pipeline 3 into the casting mold. One end of each of these struts 6 then rests loosely on the inner wall of the pipeline 3. The other ends of the struts 6 face each other and are connected to each other. Here, too, at least a portion of the channels 7 through which the temperature control medium can flow is formed by adjacent struts.

[0064] 6 formed.

[0065] In the cross-section perpendicular to the longitudinal direction of the tubular functional element 3, an envelope of an outer contour of the insert part rests, at least in sections, against an envelope of the inner contour of the tubular functional element. The ends of the struts 6, which rest loosely against the inner wall of the tubular functional element 3, rest on the envelope of the outer contour of the insert part, and the inner wall of the tubular functional element 3 forms the envelope of the inner contour of the tubular functional element 3.

[0066] Furthermore, the ends of the struts 6 facing the inner wall of the pipeline 3 are provided with support surfaces 6a, which bear against the inner wall of the pipeline 3. Such support surfaces 6a can improve the introduction of the forces acting on the pipeline 3 during casting into the struts 6 of the insert 5. Furthermore, the support surfaces 6a are also advantageous during later operation with regard to heat transfer, since thermal energy absorbed from the base body 1a is transferred more quickly to the support structure 2 and, due to the surface area in the pipeline 3 increased by the support structure 2, is transferred more effectively to the temperature control medium flowing in the pipeline 3.

[0067] Fig. 8d shows a sectional view of Fig. 6 along section CC' with the support structure 2 according to Fig. 8a. Shown is one of the pipe ends 3c, 3d, each formed by a pipe end section of the pipeline 3 extending from the casting mold. These pipe ends 3c, 3d are not encased in base material after casting. The formations of the pipe ends 3c, 3d can be formed before, during, or after the pipeline 3 is inserted into the casting mold, or after it is removed from the casting mold after casting.

[0068] A further exemplary embodiment of the support structure 2 is shown in Fig. 9a to Fig. 9c. Here, too, the support structure 2 has struts 6 arranged in a cross-section perpendicular to the flow direction of the pipeline 3 and radially to the axis of symmetry of the pipeline 3. However, the struts 6 are each fastened at one end to the inner wall of the pipeline 3. Such a pipeline 3 with internally fastened struts 6 can be formed, for example, using the extrusion process. The other ends of the struts 6 face one another and are spaced apart from one another. Before, during, or after the pipeline 3 with the struts 6 is inserted into the casting mold, a strand-shaped insert 5 in the form of a tubular element is then inserted between the mutually facing ends of the struts 6. The mutually facing ends of the struts 6 then rest on an outer circumferential surface of the insert 5 designed as a tubular element.For the temperature control medium, flowable channels 7 are formed between the adjacent struts 6, and a channel 4 is formed by the insert 5. In a design not shown, however, a rod element can also be inserted instead of the tube element. This can be advantageous from a stability perspective. Optionally, the pipeline 3 with the inserted rod or tube element (insert 5) is bent before being inserted into the mold.

[0069] In the cross-section perpendicular to the longitudinal direction of the tubular functional element 3, an envelope of an outer contour of the insert part rests, at least in sections, against an envelope of the inner contour of the tubular functional element. The ends of the struts 6, which rest loosely on the outer surface of the rod or tubular element, rest on the envelope of the inner contour of the tubular functional element 3, and the outer surface of the rod or tubular element forms the envelope of the outer contour of the insert part.

[0070] Fig. 9d shows a sectional view of Fig. 6 along section CC' with the support structure according to Fig. 9a. One of the pipe ends 3c, 3c is shown. A pipe socket 8 is placed on this pipe end 3c, 3d before the pipeline 3 is inserted into the casting mold. A section of this pipe socket 8 is enclosed by the casting mold after the pipeline 3 has been inserted into the casting mold. Another section of this pipe socket 8 is led out of the casting mold. During casting, at least a partial section of the section of the pipe socket 8 arranged in the casting mold is then surrounded by the base body material. To form the pipe end 3a, 3b shown, the pipe element 4b projects beyond the pipe end of the pipeline 3 towards the surroundings of the casting mold when the pipeline 3 is inserted into the casting mold.The shape of the section of the pipe socket 8 which is led out of the casting mold can be shaped in its outer contour before, during or after insertion into the casting mold or after removal from the casting mold.

[0071] The invention is not limited to pipelines 3 with a round cross-section. For example, the pipeline 3 can also have an oval or elliptical cross-section.

[0072] Due to the channels 4, 7, a coolant can advantageously be passed through the pipe during casting.

[0073] The invention is not limited to the illustrated embodiments of the support structure. For example, instead of the six struts visible in the cross-section along the flow direction of the pipeline, more or fewer struts can be provided.

[0074] Preferably, the pipe end and the pipe socket 8 are designed such that in the region of the section of the pipe socket 8 lying in the casting mold, a gap 10 between an outer contour of the at least one pipe end and an inner contour of the seated pipe socket 8 is dimensioned such that in the region of the partial section of the pipe socket 8 arranged in the casting mold, base body material flows in between the pipe socket 8 and the pipe end 3c, 3d during casting.

[0075] In the above-mentioned embodiments, the insert part 5 can be produced, for example, by means of extrusion, without the invention being limited thereto.

[0076] In a design not shown, the component serves as a structural component and temperature control device, fulfilling both structural and temperature control properties.

[0077] In all the above-mentioned embodiments, the insert part 5 loosely inserted in the tubular functional element 3 can be fixed in its position along the longitudinal direction of the tubular functional element 3 - in particular when the insert part 5 is arranged only in a partial section of the tubular functional element 3 and a displacement of the insert part 5 along the longitudinal direction is to be prevented.

[0078] List of reference symbols

[0079] 1 component, structural component, tempering device

[0080] 2 Support structure

[0081] 3 tubular functional element

[0082] 3a Section of the inner wall of the tubular functional element

[0083] 3b Section of the inner wall of the tubular functional element

[0084] 3c Pipe end

[0085] 3D pipe end

[0086] 4 channel

[0087] 5 strand-shaped insert

[0088] 6 struts

[0089] 6a Support surfaces

[0090] 7 channel

[0091] 8 Longitudinal axis

[0092] 9 Longitudinal axis

[0093] 10 pipe sockets

[0094] 11 Gap between pipe end and pipe socket

Claims

Patent claims 1. A method for producing a component (1) with a base body (1a) which is formed from a component material (4) and has a tubular functional element (3) which is embedded at least in sections in the component material (4), wherein firstly the tubular functional element (3) is placed at least in sections in a casting mold and then component material (4) is introduced into the casting mold in liquid form and flows at least partially around the tubular functional element (3) and after the component material (4) has solidified, the component (1) is removed from the casting mold, characterized in that before the introduction of the liquid component material (4) into the casting mold,during or after the insertion of the tubular functional element (3) into the casting mold, at least along a section of the tubular functional element (3) arranged in the casting mold, a strand-shaped insert (5) is loosely inserted into the tubular functional element (3), and after the insertion of the strand-shaped insert (5) into the tubular functional element (3), in a cross-section perpendicular to the longitudinal direction of the tubular functional element (3), an envelope of an outer contour of the insert at least partially abuts an envelope of the inner contour of the tubular functional element (3), and with the at least partially abutting envelopes, a support structure is formed between the tubular functional element (3) and the insert (5), which support structure has opposing sections (3a,3b) the inner wall of the tubular functional element (3) is supported against each other., 2. Method according to claim 1, characterized in that the insert part (5) remains in the tubular functional element (3) after the solidification of the component material (4) and the removal of the component from the casting mold when the component (1) is used.

3. Method according to one of the preceding claims, characterized in that the support structure is formed in that the insert part (5) has struts (6) arranged radially to the central longitudinal axis of the tubular functional element (3) in the cross section perpendicular to the longitudinal direction of the tubular functional element (3), and one end of each of these struts (6) rests loosely on the inner wall of the tubular functional element (3) and the other ends the struts (6) face each other and are connected to each other, wherein the ends of the struts (6) loosely resting on the inner wall of the tubular functional element (3) lie on the envelope of the outer contour of the insert part and the inner wall of the tubular functional element (3) forms the envelope of the inner contour of the tubular functional element (3).

4. Method according to claim 1, characterized in that the support structure is formed in that the tubular functional element (3) has struts (6) arranged radially to the central longitudinal axis of the tubular functional element (3) in the cross section perpendicular to the longitudinal direction of the tubular functional element (3), and in that one end of each of these struts (6) is fastened to the inner wall of the tubular functional element (3), and the other ends of the struts (6) face each other and are spaced apart from each other, and the insert (5) is a rod or tube element and, when inserted into the tubular functional element (3), is arranged between the mutually facing ends of the struts (6), and the mutually facing ends of the struts (6) rest loosely on an outer circumferential surface of the rod or tube element,wherein the ends of the struts (6) resting loosely on the outer surface of the rod or tube element lie on the envelope of the inner contour of the tubular functional element (3) and the outer surface of the rod or tube element forms the envelope of the outer contour of the insert.

5. Method according to one of the preceding claims, characterized in that in the case of inserting the insert part (5) into the tubular functional element (3), the tubular functional element (3) with the inserted insert part (5) is bent before inserting the tubular functional element (3) into the casting mold.

6. Method according to one of the preceding claims, characterized in that the component is a structural component whose tubular functional element (3) serves to stiffen the structural component and / or that the component is a temperature control device whose tubular functional element (3) is provided for the passage of a temperature control medium.

7. The method according to claim 6, characterized in that the component material of the base body of the component is a metal, a metal alloy or a plastic with or without filler.

8. The method according to claim 7, characterized in that the filler of the plastic increases the thermal conductivity of the plastic and / or that the filler serves to increase the strength of the plastic.

9. Method according to claim 7, characterized in that in the case of a component material consisting of metal or a metal alloy, the tubular functional element (3) and / or the strand-shaped insert (5) are formed from a metal or a metal alloy.

10. Method according to claim 7, characterized in that in the case of a component material consisting of plastic, the tubular functional element (3) and / or the strand-shaped insert (5) are formed from a metal or a metal alloy or a plastic.

11. Component (1) with a base body (1a) which is formed with a component material (4) in a casting process and has a tubular functional element (3) which is embedded at least in sections in the base body of the component (1) constructed by the casting process, characterized in that an insert (5) is loosely inserted in the tubular functional element (3) and that in a cross-section perpendicular to the longitudinal direction of the tubular functional element (3), an envelope of an outer contour of the insert at least partially abuts an envelope of the inner contour of the tubular functional element (3) and that with the at least partially abutting envelopes, a support structure is formed between the tubular functional element (3) and the insert (5), which support structure has opposing sections (3a,3b) the inner wall of the tubular functional element (3) is supported against each other., 12. Component according to claim 11, characterized in that the insert part (5) loosely inserted in the tubular functional element (3) is fixed in its position along the longitudinal direction of the tubular functional element (3).

13. Component according to one of claims 11 or 12, characterized in that the insert part (5) has struts (6) arranged radially to the central longitudinal axis of the tubular functional element (3) in the cross section lying perpendicular to the longitudinal direction of the tubular functional element (3), and one end of each of these struts (6) rests loosely on the inner wall of the tubular functional element (3) and the other ends of the struts (6) face one another and are connected to one another, wherein the ends of the struts (6) loosely resting on the inner wall of the tubular functional element (3) lie on the envelope of the outer contour of the insert part and the inner wall of the tubular functional element (3) forms the envelope of the inner contour of the tubular functional element (3).

14. Component according to claim 11, characterized in that the tubular functional element (3) has struts (6) arranged radially to the central longitudinal axis of the tubular functional element (3) in the cross section perpendicular to the longitudinal direction of the tubular functional element (3), and in that one end of each of these struts (6) is fastened to the inner wall of the tubular functional element (3), and the other ends of the struts (6) face each other and are spaced apart from each other, and the insert (5) is a rod or tube element, and when inserted, this tubular functional element (3) is arranged between the mutually facing ends of the struts (6), and the mutually facing ends of the struts (6) rest loosely on an outer circumferential surface of the rod or tube element,wherein the ends of the struts (6) resting loosely on the outer surface of the rod or tube element lie on the envelope of the inner contour of the tubular functional element (3) and the outer surface of the rod or tube element forms the envelope of the outer contour of the insert.

15. Component according to one of claims 11 to 14, characterized in that the component is a structural component and its tubular functional element (3) serves to stiffen the structural component or that the component is a tempering device whose tubular functional element (3) is provided for the passage of a tempering medium.

16. Component according to claim 15, characterized in that in the case of the temperature control device, the mutually facing ends of the struts (6) are connected to one another via a channel element arranged along the tubular functional element (3) and / or that channels through which the temperature control medium can flow are formed between the struts (6) along the tubular functional element (3).

17. Component according to one of claims 11 to 15, characterized in that the component material of the base body of the component is a metal or a with or without plastic with filler.

18. Component according to claim 17, characterized in that the filler of the plastic increases the thermal conductivity or the rigidity of the plastic.

19. Component according to one of claims 15 to 18, characterized in that in the case of the temperature control device, cooling fins are provided on the base body (1a).

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