Structural component for a vehicle and method for the production thereof

Abstract

The invention relates to a structural component as a composite component (1-10) for a vehicle, in particular for a bicycle, which is obtained by injection moulding from a thermoplastic material preferably filled with tension-resistant short fibres, wherein the structural component comprises a further fibre reinforcement (14-17) at least in a partial region, wherein the further fibre reinforcement comprises tension-resistant long fibres (201, 505), wherein the tension-resistant long fibres are moulded around or on the filled thermoplastic material as at least one insert part in an injection moulding tool, wherein the insert part is selected from a group of insert parts comprising strips of unidirectional, preferably continuous fibres, semipregs of woven fibre fabrics or laid fibre fabrics, prepregs of woven fibre fabrics or laid fibre fabrics or organometallic sheets as dimensionally stable semifinished products with unidirectionally oriented or multidirectionally laid or woven tension-resistant long fibres, and wherein at least some of the insert parts comprise a thermoplastic material as a matrix material.

Description

[0001] STRUCTURAL COMPONENT FOR A VEHICLE AND METHOD FOR THE PRODUCTION THEREOF

[0002] The invention relates to a structural component as a composite component for a two-wheeler, in particular for a bicycle, which is obtained by injection molding from a thermoplastic material preferably filled with high-tensile short fibers. The invention further relates to a method for producing such a structural component.

[0003] Composite components made from fiber composite materials are generally known from the prior art. It is also known to manufacture bicycle parts, such as bicycle cranks or handlebars, from fiber composite materials. Composite components made from carbon in particular are widespread in the course of weight optimization of bicycles. Temperature-curing plastics, in particular epoxy resin, are largely used as matrix materials. The fibers used in the prior art are usually glued together as woven fabrics or non-crimp fabrics according to a predetermined cut and inserted into a tool by hand. A plastic based on epoxy resin, for example, is introduced into the closed tool in such a way that the resin penetrates the fiber woven fabric or fiber non-crimp fabric. The component is then cured by the application of temperature.This manufacturing process is complex and requires a high degree of manual work, both before the component is formed and in the form of the necessary rework.

[0004] The stability of the bicycle frame and all other structural components is particularly important in vehicle frames or bicycle frames for electrically powered bicycles, as an energy storage device is usually either permanently installed in the bicycle frame or detachably arranged in a suitably designed frame compartment. Such a frame compartment, particularly when integrated into the bicycle frame, means a structural weakening of the frame profile or a reduction in the area moment of inertia of the relevant cross-section. This is particularly critical for bicycle frames for electric vehicles, as these have to absorb a higher weight, larger bending moments and larger drive torques, as well as greater reaction forces when braking.

[0005] From DE 10 2021 126 601 A1, for example, a vehicle frame for an electrically driven vehicle, in particular for a bicycle, is known, which is designed as a one-piece component and which has at least one layer made of fiber composite material, wherein the vehicle comprises at least one electrical energy store which comprises at least one energy storage cell, wherein the energy store is arranged in the frame element and the energy store is non-detachably fixed to the frame element by means of casting with resin and by means of foaming with a foaming agent. The frame element comprises one or more layers made of fiber composite material which is impregnated with a replaceable resin and cured. Such a vehicle frame is complex to manufacture and not sustainable from an environmental point of view, since the materials are difficult to separate and difficult to recycle.This particularly applies to fiber composite materials that form a bond with cured resins.

[0006] Furthermore, it is generally known in the prior art to provide carbon fiber-reinforced bicycle frames / carbon frames for bicycles with particularly structurally stressed areas of the frame, such as axle mounts, dropouts, or the like, with additional metal inserts or reinforcements. For example, DE 20 2007 008 86 U1 discloses a bicycle frame mounting device for receiving a wheel axle, on which at least one metal reinforcement plate is arranged.

[0007] DE 10 2016 015 538 A1 discloses a method for producing a bicycle frame from a number of modules, each of which is obtained by injection moulding using fluid injection technology. The fluid injection technology method offers a technically advantageous option for forming the individual components as hollow bodies with optimised weight. However, such a method has the disadvantage that the components do not have a constant and defined wall thickness and, in particular, do not have a consistently smooth surface within the cavities. This is not advantageous for a variety of reasons. This results, for example, in differences in mass between components in a series. It may also make it more difficult to feed cables through the frame.

[0008] The invention is based on the object of providing a structural component for a vehicle, in particular for a bicycle, for example for an electric bicycle, which, on the one hand, is easy to manufacture and, on the other hand, is at least partially structurally designed to be load-optimized. In particular, the invention is also based on the object of providing a method for manufacturing such a structural component, which enables the component to be manufactured as simply as possible.

[0009] The object is achieved by a structural component having the features of claim 1 and by providing a method for producing this structural component having the features of claim 18.

[0010] Advantageous embodiments of the invention emerge from the subclaims.

[0011] According to one aspect of the invention, a structural component is provided as a composite component for a vehicle, in particular for a bicycle, which was obtained by injection molding from a thermoplastic material preferably filled with tensile short fibers, wherein the structural component comprises a further fiber reinforcement at least in at least one partial area, wherein the further fiber reinforcement comprises tensile long fibers, wherein the tensile long fibers are overmolded or injection-molded as at least one insert in an injection mold with a filled thermoplastic material, wherein the insert is selected from a group of inserts comprising strips of unidirectional, preferably endless fibers, semipregs of fiber fabrics or fiber layups,Prepregs made of fiber fabrics or fiber wovens or organic sheets as dimensionally stable semi-finished products with unidirectionally oriented or multidirectionally laid or woven tensile long fibers, and wherein at least some of the inserts comprise a thermoplastic as matrix material.

[0012] A structural component within the meaning of the present invention is a component on a vehicle, in particular on a bicycle, which is subjected to structural stress when used as intended, i.e. to operating forces caused by the user or forces resulting from riding. A structural component in this sense will therefore generally be a component that is subject to tensile and / or bending stress. However, the term vehicle within the meaning of the present invention does not primarily include two-wheelers, in particular bicycles. In principle, the invention can also relate to tricycles, recumbent bicycles or the like.

[0013] Thermoplastics in particular are not suitable for withstanding permanent tensile loads or permanent bending loads or major alternating loads without further material strengthening measures.

[0014] Additional fiber reinforcement refers to the targeted reinforcement of the structural component using high-tensile long fibers. The additional fiber reinforcement is preferably an integral component of the injection-molded component and can be completely integrated into the injection-molded material in a non-visible manner. In principle, however, the additional fiber reinforcement can also be visibly integrated into the injection-molded material, such that the additional fiber reinforcement forms an outer side or part of the outer surface of the structural component.

[0015] Although a thermoplastic filled with high-tensile short fibers is particularly preferred as the filled thermoplastic according to the invention, other fillers that increase the strength of the thermoplastic can also be considered. For example, so-called beads or minibeads or even flakes can be considered as alternatives to fiber fillings. Glass fibers and / or carbon fibers are generally considered as fillers.

[0016] A particular advantage of the structural component according to the invention is that it can be manufactured very easily by injection molding in a single manufacturing cycle.

[0017] The structural component according to the invention was particularly preferably obtained by a conventional injection molding process, in which any cavities provided or at least one cavity in the component were produced, if necessary, by means of at least one slider and / or with at least one core inserted into the tool and / or with at least one dimensionally stable insert part inserted into the tool and over-molded, for example in the form of a dimensionally stable hollow profile inserted into the tool. The term core in the sense of the present application also includes so-called lost cores made of a material that can be removed or dissolved after completion of the structural component.

[0018] Preferably, the structural component according to the invention has a constant wall thickness, particularly in the region of at least one cavity provided in the structural component. A constant wall thickness is understood to mean a uniform wall thickness, which also includes a constantly changing, defined wall thickness, which is structurally predetermined for reasons of optimizing the mold's deformability.

[0019] Furthermore, the structural component particularly preferably has a smooth and uniform inner surface at least in the region of a cavity. The surface preferably has a surface roughness that corresponds to the surface quality that was produced by electroresistive machining of the cavity of the mold. The surface quality according to standard VDI 3400 can be between 12 and 45, which corresponds to a surface roughness Ra between 0.4 and 18 pm. At least in parts, the structural component according to the invention can have a cross-section without continuous cavities, i.e. for example a chambered cross-section. In these regions, the structural component according to the invention can have a perforated outer surface with at least one depression in the cross-section of the structural component. This depression can be provided with at least one stiffening rib that can preferably be demolded without a slide.

[0020] The semipregs, prepregs, or organic sheets provided or used according to the invention are preferably exclusively thermoplastic semipregs, prepregs, and organic sheets, i.e., with a thermoplastic matrix material that preferably corresponds to the thermoplastic base material of the structural component. The base material used is preferably a single-grade PA6. However, recyclates can also be considered as base materials.

[0021] A semipreg, as defined in this application, is a fiber fabric or fiber mat to which the thermoplastic matrix material is applied and melted as a polymer powder. Prepregs, as defined in this application, are fabrics or mats, possibly multi-layered, that are already completely impregnated with the thermoplastic matrix material.

[0022] Organic sheets in the sense of the present invention are understood to mean completely consolidated and impregnated, preferably dimensionally stable semi-finished products, which may also optionally be formed in multiple layers.

[0023] Preferably, the thermoplastic matrix material of the semipregs, prepregs or organic sheets provided for in the application consists of the same base plastic as the base plastic of the injection-molded thermoplastic material used.

[0024] The term "insert" within the meaning of the present invention refers to a structure in the form of oriented long fibers, which may be woven or laid, even in multiple layers. The insert does not necessarily have to be dimensionally stable or self-supportingly rigid. The term "insert" is intended to imply that the structure in question was introduced into an injection mold prior to the injection molding process and was held or fixed in a specific position therein during the injection molding process, so that the insert is overmolded or molded onto the structural component according to the invention.

[0025] By providing additional fiber reinforcement made of long fibers, it is possible to specifically reinforce critical and particularly structurally stressed areas of the component against the expected tensile or bending load. Targeted reinforcement against expected tensile and / or bending loads plays a particularly important role when using thermoplastics, since the thermoplastic exhibits a certain tendency to flow. This makes it possible, in particular, to dimension the structural component according to the invention in such a way that excessive mass accumulation of the thermoplastic material is avoided, since such mass accumulation is accompanied by varying shrinkage during curing or solidification of the plastic after the injection molding process.

[0026] The fiber fabrics provided according to the invention can be formed in one or more layers, wherein the fibers can be aligned multidirectionally and, in particular, can be oriented with regard to the expected stress on the insert in the installed position of the structural component. A further particular advantage of the structural component according to the invention is that it is fully recyclable, since it is particularly preferably produced entirely without heat-curing resins, in particular without the use of epoxy resin. The structural component according to the invention particularly preferably comprises only a single type of thermoplastic.

[0027] The structural component according to the invention can be selected from a group of structural components comprising frames, frame parts, saddles, seat posts, forks, handlebar stems, wheels, spokes, clamps, hub bodies, cranks, and the like. In particular, wheels, their flanks, and / or their spokes can be designed to be load-optimized according to the invention. In particular, spokes that, depending on the configuration of the wheel, are subjected almost exclusively to tensile stress can be reinforced, for example, in the tensile direction with unidirectionally oriented continuous fibers.

[0028] The handlebar of a bicycle handlebar as a structural component can be reinforced with high-tensile continuous fibers at least over a partial length and / or over a partial circumference. For example, it can be reinforced with unidirectionally oriented continuous fibers on an upper side in the region of the neutral fiber of the cross-section.

[0029] In the following, the terms top and bottom as well as top or bottom refer to the component in its installed position on the vehicle and to the perspective of a user sitting on the vehicle.

[0030] A structural component within the meaning of the invention can in particular be a profile or a profile section of a bicycle frame. Areas of a bicycle frame that are particularly subject to stress are, for example, the chainstays, particularly the rear swing arm on full-suspension bicycles, the head tube, the down tube and the bottom bracket shell, the transition from the down tube to the bottom bracket shell and the dropouts of the chainstays, particularly in the area of ​​the axle mount. The term "chainstays" chosen here does not exclude the corresponding component on a bicycle with a toothed belt drive. According to the invention, fiber reinforcement with long fibers that are oriented according to the expected loads can be provided in these areas.

[0031] In one variant of the structural component according to the invention, the insert part can have a substantially at least partially closed cross-sectional contour, preferably in the form of a box-shaped or tubular hollow cross-section. Such a contour can be advantageous, for example, in the case of an insert part which reinforces a profile or a profile section of the bicycle frame, for example in the top tube of the bicycle frame. In some bicycle frames, the volume of a bicycle frame designed as an open profile is partially used as storage space. This results in the profile cross-section of the bicycle frame naturally having a lower area moment of inertia in these areas. In such a case, it is particularly advantageous according to the invention to adapt the contour of the insert part to the partially open contour of the frame profile, for example in the form of a C profile or a U profile.

[0032] In a variant of the structural component according to the invention, it can be provided that this comprises at least one insert part designed as a fiber fabric or fiber layup, which has been overmolded or injection-molded as an insert part without a matrix material, in such a way that the injected, filled thermoplastic material at least partially penetrates and / or encloses the fiber fabric or fiber layup, so that the impregnation of the fiber fabric or fiber layup takes place quasi in situ.

[0033] For example, it may be provided that the insert is provided as a fabric stocking or fabric tube that is not dimensionally stable before the structural component is manufactured.

[0034] In a variant of the structural component according to the invention, in which the structural component is designed as a profile or profile section of a bicycle frame, it is provided that the insert is arranged in a largely closed profile chamber of the bicycle frame or is integrated into a wall of the closed profile chamber and / or at least partially encloses it, wherein the profile chamber extends in the longitudinal direction of a frame profile and is preferably arranged within the frame profile in the region of an expected tensile stress during intended use of the bicycle frame.

[0035] In particular, if the profile section forms a top tube or a down tube or a seat tube of the bicycle frame, the profile section can have an open, preferably U-shaped cross-sectional profile.

[0036] In a preferred variant of the structural component according to the invention, this is designed as a frame profile of an electric bicycle, wherein in particular the profile section additionally reinforced with long fibers forms a frame compartment and / or at least partially encloses a frame compartment. In such an area of ​​the bicycle frame, the frame is structurally dimensioned so generously that the battery or the electrical energy storage device can be inserted into it. This leads to appropriately dimensioned frame cross-sections so that the energy storage device can be easily pushed in and received. In particular, the frame cross-section in this area of ​​the bicycle frame cannot be closed, which gives rise to special design requirements, in particular if the battery storage device is to be removable from the frame by the user of the electric bicycle, i.e. is not a load-bearing component of the bicycle frame.

[0037] According to the invention, it can be provided, for example, that the structural component or the profile or the profile section of the bicycle frame forms a continuously closed profile cross-section designed as a hollow profile in the region of the frame compartment and, within the same cross-section, also a partially open profile cross-section which is designed as a frame compartment or forms part of the frame compartment. In this case, it is advantageous, for example, if the insert extends at least within the continuously closed hollow profile or is integrated into the wall of the closed hollow profile. This region of the frame profile is subject to particular stress, in particular due to the additional weight of the electrical energy storage device.

[0038] In a variant of the structural component according to the invention, in which it is designed, for example, as a handlebar or seat post, the insert can comprise at least one overmolded or molded-on continuous fiber-reinforced tape with unidirectionally aligned, high-tensile long fibers in the form of continuous fibers. The insert can be designed as a so-called "UD tape."

[0039] The thermoplastic material filled with tensile short fibers (base material of the structural component) can have a filling level of 20 to 60 percent by weight, based on the total weight of the structural component. The tensile short fibers can have a fiber length of 0.1 to

[0040] 50 mm, preferably a fiber length of 0.1 to 1 mm.

[0041] The high-tensile long fibers can have a fiber length greater than 50 mm and, for example, a fiber length that approximately corresponds to the largest dimension of the structural component. If the structural component is designed as a handlebar, for example, the long fibers can have a length that corresponds to the length or width of the handlebar.

[0042] The thermoplastic plastic or base material of the structural component and / or the thermoplastic matrix material is preferably selected from a group of plastics comprising PA, PP, PPA, PS, PE, PE, ABS, PC, POM, PEK, PEEK, PA610, HPPA, PARA, PBT, PK.

[0043] The tensile long fibers are preferably selected from a group of fibers comprising carbon fibers, glass fibers, aramid fibers, Kevlar fibers and basalt fibers.

[0044] The object underlying the invention is further achieved by providing a method for producing the structural component described above.

[0045] The method according to the invention comprises the following process steps:

[0046] Providing an injection molding arrangement with at least one injection unit with means for plasticizing and providing a plasticized filled plastic under pressure into a tool with at least one cavity, and wherein the at least one cavity at least partially defines the shape of the structural component and has at least one sprue, inserting and fixing at least one insert part into at least one partial cavity of the tool, wherein the insert part is selected from a group of insert parts comprising strips of unidirectional, preferably endless fibers, semipregs of fiber fabrics or fiber layups, prepregs of fiber layups or fiber fabrics or organic sheets as dimensionally stable semi-finished products with unidirectionally oriented or multidirectionally laid or woven tensile long fibers, and wherein at least some of the insert parts comprise a thermoplastic plastic as a matrix material,

[0047] Injecting the plasticized plastic under pressure into the closed tool and

[0048] Opening the tool and removing the finished product.

[0049] The structural component is preferably manufactured in a single injection molding cycle.

[0050] The structural component according to the invention is particularly preferably obtained by a conventional injection molding process, in which any cavities provided or at least one cavity in the component are produced, if necessary, by means of at least one slider and / or with at least one core inserted into the tool and / or with at least one dimensionally stable insert part inserted into the tool and over-molded, for example in the form of a dimensionally stable hollow profile inserted into the tool. The term core in the sense of the present application also includes so-called lost cores made of a material that can be removed or dissolved after completion of the structural component.

[0051] Preferably, the structural component according to the invention is injection-molded with a constant wall thickness, particularly in the region of at least one cavity provided in the structural component. A constant wall thickness is understood to mean a uniform wall thickness, which also includes a constantly changing, defined wall thickness, which is predetermined by the design for reasons of optimizing the mold's demoldability.

[0052] Furthermore, the structural component is particularly produced with a smooth and uniform inner surface, at least in the region of a cavity. It goes without saying that the outer surface or lateral surface of the structural component also has a corresponding surface quality. The surface preferably has a roughness depth that corresponds to the surface quality produced by electroresistive machining of the mold cavity. The surface quality according to standard VDI 3400 can be between 12 and 45, which corresponds to a surface roughness Ra between 0.4 and 18 pm.

[0053] The injection mold can, for example, comprise at least two partial cavities that, when closed, define the contour of the structural component. If, for example, at least one strip of unidirectional continuous fibers is provided as an insert, this strip can either be inserted into a partial cavity of the injection mold or at least temporarily attached to a wall of the partial cavity by means of an adhesive.

[0054] If the insert is designed, for example, as a dimensionally stable organic sheet, it can be inserted into a partial cavity. Positional fixation can, for example, only be achieved when the injection mold is closed, for example by the interaction of two halves of the injection mold. Alternatively, the method can comprise, for example, a dimensionally unstable insert, for example in the form of a fabric stocking, fabric hose, or the like, being positioned in at least one cavity or partial cavity of the mold before the injection molding process.

[0055] Finally, the method may include inserting a nonwoven fabric or woven fabric into a partial cavity of the mold in contact with the mold wall. Both the nonwoven fabric and the woven fabric may be multi-layered. The nonwoven fabric may be configured such that the tensile fibers of the nonwoven fabric are oriented multidirectionally.

[0056] The method may comprise the step of cutting and aligning the tensile fibers of at least one strip with continuous fibers and / or at least one fabric with unidirectionally or multidirectionally oriented tensile fibers as long fibers, before and / or during insertion into the molding tool.

[0057] The method further preferably comprises the alignment of the insert and / or the tensile long fibers within the molding tool in the main loading direction assumed for the structural component at least in some areas.

[0058] Preferably, at least one thermoplastic filled with tensile short fibers is used as the injected thermoplastic or as the base material.

[0059] Preferably, the thermoplastic material filled with tensile short fibers has a filling level of 20 to 60 percent by weight based on the total injected mass or based on the total weight of the structural component.

[0060] The tensile short fibers can have a fiber length of 0.1 to 50 mm, preferably a fiber length of 0.1 to 1 mm.

[0061] The tensile long fibers used to provide the at least one insert can have a fiber length greater than 50 mm.

[0062] In the method according to the invention, it can be provided that the injected thermoplastic plastic and / or the thermoplastic matrix material of at least one insert part is selected from a group of plastics comprising PA, PP, PPA, PS, PE, PE, ABS, PC, POM, PEK, PEEK, PA610, HPPA, PARA, PBT, PK.

[0063] The tensile long fibers used to provide at least one insert can be selected from a group of fibers comprising carbon fibers, glass fibers, aramid fibers, Kevlar fibers and basalt fibers.

[0064] The invention is explained below with reference to and with reference to an embodiment shown in the accompanying drawings.

[0065] It shows :

[0066] Figure 1 is a perspective sectional view of a structural component according to the present invention as a bicycle frame of an electric bicycle,

[0067] Figure 1A is a detail enlargement of detail A in Figure 1,

[0068] Figure 2A shows a first variant of a profile cross-section of the frame tube of the bicycle frame according to Figure 1,

[0069] Figure 2B shows a second variant of a profile cross-section of the frame tube of the bicycle frame according to Figure 1,

[0070] Figure 3A is a perspective view of the bicycle frame according to Figure 1 with the frame compartment open,

[0071] Figure 3B is an enlarged view of the opened frame compartment from the direction of the arrow shown in Figure 3A,

[0072] Figure 4A is a perspective exploded view of the bicycle frame according to Figure 1 with a fiber reinforcement in the area of ​​the seat tube,

[0073] Figure 4B is a perspective view of the bicycle frame shown in Figure 4A,

[0074] Figure 5 is a perspective view of a variant of a bicycle frame as a structural component according to the invention,

[0075] Figure 6 is a perspective front view of the bicycle frame shown in Figure 1,

[0076] Figure 7A is a rear view of the bicycle frame shown in Figure 1,

[0077] Figure 7B is a detailed view of the rear swing arm of the bicycle frame shown in Figure 7A,

[0078] Figure 8 is a perspective view of another variant of a bicycle frame as a structural component according to the invention,

[0079] Figure 9A shows a further variant of a bicycle frame as a structural component according to the invention,

[0080] Figure 9B is a representation of detail B in Figure 9A

[0081] Figure 10A is a perspective view of a bicycle frame constructed in accordance with the bicycle frame of Figure 1, Figure 10B is a detail of the bicycle frame of Figure 10A,

[0082] Figure 11 is a perspective view of a fork for a bicycle frame as a structural component according to the invention,

[0083] Figure 12 shows a view of a seat post as a structural component for a bicycle,

[0084] Figure 13 is a perspective view of a wheel as a structural component for a bicycle,

[0085] Figure 13A is an enlarged view of detail A in Figure 13,

[0086] Figure 14A is a perspective view of an integrated handlebar as a structural component according to the invention,

[0087] Figure 14B is a perspective bottom view of the integrated handlebar according to Figure 8A,

[0088] Figure 14C is a perspective rear view of the integrated handlebar according to Figure 8A and

[0089] Figure 15 is a perspective view of a crank arm made of thermoplastic material with a partial reinforcement made of long fibers as a structural component in the sense of the present invention.

[0090] A variant of a structural component according to the invention is embodied, for example, by the bicycle frame 1 shown in partial section in Figure 1 as a bicycle frame 1 for an electric bicycle. Although the structural components described below in the exemplary embodiments, in particular the bicycle frame 1, are described as components that are particularly suitable for use with an electric bicycle, the invention is fundamentally not limited to electric bicycles and their components.In principle, however, the design of electric vehicles presents the designer with special requirements with regard to the stability of the bicycle frame 1 , since on the one hand many frame designs deviate from the classic truss structure (diamond frame) and on the other hand the stability of frame tubes is impaired or particularly stressed by the integration of electronic components and / or rechargeable batteries / batteries and / or motor components (motor bracket / motor gear box).

[0091] The bicycle frame 1 shown in Figure 1 is predominantly made of thermoplastic material which is filled with high-tensile short fibers, for example in the form of glass fibers. The bicycle frame 1 can, for example, have been injection-molded in one piece. The bicycle frame 1 comprises the usual frame components, such as a seat tube 2, seat stays 3, chain stays 4, and a down tube 5 which is connected to the seat tube 2 and which forms a mount 6 for a gearbox and / or a motor in a connection area with the seat tube 2. The down tube 5 is designed as a box-shaped profile which, from the perspective of a rider, is open downwards and forms a frame compartment 7 for receiving a removable battery. At the upper end of the down tube 5 facing the rider, a head tube 8 for receiving a headset and a fork shaft is formed in a known manner.

[0092] The bicycle frame 1 shown in the figures is provided according to the invention at least in partial areas with a further fiber reinforcement which is integrated into the filled thermoplastic of the structural component, wherein this fiber reinforcement comprises high-tensile long fibers, for example carbon fibers, which are preferably arranged and aligned in the component according to the expected load on the structural component, wherein the high-tensile long fibers have been overmolded or injection-molded with the filled thermoplastic as at least one insert in an injection mold. As already described at the beginning, the long fibers can be single-layered or multi-layered, unidirectionally or multidirectionally oriented.

[0093] 1A to 2B, the down tube 5 comprises a box-shaped profile which, in the variant shown in cross section in Figure 2A, is designed as a U-shaped profile which is open on the underside of the frame and which encloses a closed reinforcing profile 9, for example in the form of a thermoplastic organic sheet or a thermoplastic prepreg, which was overmolded as an insert to form the contour shown in Figures 2A, B, in such a way that the reinforcing profile 9 has entered into a material-fit connection with the profile of the down tube 5. The reinforcing profile 9 integrated into the down tube 5 can comprise a fiber fabric or a fiber fabric made of long fibers.The arrangement within the bicycle frame 1 is selected such that, on the one hand, the profile cross-section of the down tube 5 is supplemented to form a closed profile with a correspondingly higher area moment of inertia and that this is arranged in the area of ​​the highest expected bending stresses of the bicycle frame 1 (Fig. 2A).

[0094] In an alternative embodiment of the cross-sectional profile of the down tube 5 according to Fig. 2B, the frame profile forms a profile chamber 19 extending over the length of the down tube 5, within which the reinforcing profile 9 extends.

[0095] Figure 1 shows a variant of a partially reinforced structural component according to the invention. For example, various areas of the bicycle frame 1 according to the invention can be reinforced with long fibers to accommodate expected higher structural stresses. Various variants of the bicycle frame 1 are described below, which can be embodied both alternatively and cumulatively in a single embodiment according to the invention.

[0096] Figures 3A and 3B show a variant of the bicycle frame 1, in which the frame compartment 7 in the area of ​​a frame compartment base 10 in the area of ​​passages 11 is provided with a fiber fabric or a fiber layup in the form of a flat structural reinforcement 12 in the manner according to the invention.

[0097] Figures 4A and 4B show a further variant of a bicycle frame 1 according to the invention, in which the upper section of the seat tube 2 is correspondingly reinforced. This section absorbs the bending forces introduced into the bicycle frame 1 via a seat post 200 (see Figure 12) via the body weight of the user. The fiber reinforcement of the seat tube 2 comprises two approximately shell-shaped reinforcement layers 20A and 20B, which form part of the outer surface of the seat tube 2 or are integrated into the wall of the seat tube 2, such that the seat tube 2 is reinforced in the direction of the main bending stress, i.e. forwards and backwards in the direction of travel.

[0098] Figure 5 shows a variant of the bicycle frame 1 as a structural component according to the invention, in which the frame geometry is designed differently from the frame geometry of the bicycle frame 1 according to Figure 1. The bicycle frame 1 according to Figure 5 comprises a top tube 13 which forms a force flow with the seat stays 3. The bicycle frame 1 according to Figure 5 is provided with a node reinforcement 14 on the underside in the area of ​​the force node of the connection of the down tube 5 to the head tube 8. As with all embodiments according to the invention, the node reinforcement 14 is also designed as a fiber fabric or fiber layup made of tensile long fibers.

[0099] Figure 6 shows a variant of the bicycle frame 1 according to the invention, which corresponds in terms of frame geometry to the variant shown in Figure 1. The bicycle frame 1 according to Figure 6 is reinforced with a tubular or shell-shaped head tube reinforcement 15 as a fiber fabric or fiber scrim made of tensile long fibers.

[0100] Figures 7A and 7B show a further embodiment of the invention, wherein Figure 7 shows a rear view of the bicycle frame 1 with a frame geometry according to Figure 5, in which the rear frame in the area of ​​the connection of the chain stays 4 to the mount 6 for the gearbox and / or motor is provided with a rear frame reinforcement 16, the operating principle of which corresponds to that of the node point reinforcement 14.

[0101] Figure 8 shows a variant of the bicycle frame 1 according to Figure 5, in which a node reinforcement 14 is provided in the area of ​​the connection of the seat tube 2 to the mount 6 for the motor and / or transmission in the area facing forward in the direction of travel. In a vehicle which is not designed as an electric vehicle, a corresponding reinforcement of a bottom bracket shell for receiving a bottom bracket would be provided. Figures 9A and 9B show a bicycle frame 1 as a structural component which corresponds approximately to the one according to Figures 5 and 8, wherein there an interface reinforcement 17 is provided at fastening openings and / or passages through the wall of the bicycle frame 1, which interface reinforcement is designed corresponding to the flat structural reinforcement 12.

[0102] Figure 10A shows a variant of the bicycle frame 1 according to Figure 1, in which the dropouts 18 with passages for thru-axles are also provided with an interface reinforcement 17, which is designed corresponding to the flat structural reinforcement 12. A further interface reinforcement 12 is provided in the area of ​​mounting bases 21 for brake calipers of a hydraulic disc brake.

[0103] Figure 11 shows the fork 300 of a bicycle, which is designed as a structural component according to the invention. The fork 300, like all other structural components described in the present application, is made entirely of thermoplastic material. The fork 300 comprises, in a known manner, a fork shaft 301 which, in the region of its connection to the fork crown 302, is provided with a fork shaft reinforcement 303 made of woven or laid long fibers. The design of the fork shaft reinforcement 303 essentially corresponds to the design of all other partial reinforcements of the structural component according to the invention. According to the invention, the fork crown 302 can also be reinforced accordingly.

[0104] As already mentioned above, in Figure 12 a seat post 200 is designed as a structural component according to the invention. The base body of the seat post 200 is also produced from a filled thermoplastic base material by injection molding and is additionally reinforced with unidirectionally aligned continuous fibers 201. The continuous fibers 201 can, for example, have been inserted into the tool during injection molding in the form of a so-called UD tape. In addition, the seat post 200 comprises at least one reinforcing patch 202, which is arranged in a highly stressed area of ​​the seat post, for example in the area in which the seat post 200 is enclosed with a screw clamp or a clamp in the installed position.

[0105] Figure 13 shows a perspective view of a wheel 400 made entirely of thermoplastic material, in which highly stressed areas, such as the rim flanks 401, the spokes 402, and the hub body 403, can be reinforced with long fibers according to the inventive concept. As can be seen from the detail in Figure 13A, the invention can provide for the spokes 402 to be reinforced accordingly in the area of ​​their connection to the rim profile.

[0106] Figures 14 A to 14 C show an integrated handlebar 500 which is made entirely of thermoplastic material and is partially reinforced with long fibers. The handlebar 500 comprises a central section 501, two handlebar arm sections 502 and two grip sections 503. An integrated handlebar in the sense of the present invention is a handlebar which is provided with an integrally molded stem 504 made of thermoplastic material, which is designed for clamping onto a fork shaft, for example a fork which is also made entirely of thermoplastic material. The invention is described with reference to the exemplary embodiment using an integrated handlebar. However, the principle of partial fiber reinforcement on the handlebar 500 is transferable to a handlebar bracket of a non-integrated handlebar with a central section designed for clamping.

[0107] In the described handlebar 500, a further fiber reinforcement in the form of unidirectional continuous fibers 505 is provided, which were inserted into the injection molding tool, for example as a so-called "UD tape," before the injection process and were molded on and / or partially overmolded. The continuous fibers 505, for example as carbon fibers or the like, extend continuously from one handlebar end to the other handlebar end and on the outside of the handlebar bracket or in the outer surface of the handlebar bracket. Furthermore, as shown in Figure 14A, a further reinforcement with continuous fibers 505 can be provided in the central section 501, wherein the continuous fibers 505 extend in the region of the central section 501 of the handlebar 500 transversely to those continuous fibers 505 that run in the outer surface of the handlebar bracket.

[0108] Figure 14 B shows a rear view of the handlebar according to 14 A, in which a node reinforcement 506 is additionally provided in the area of ​​the connection of the integrated stem 504 to the central section 501 of the handlebar 500.

[0109] Figure 14 C finally shows a perspective view of the handlebar 500 according to Figure 1 in the direction of travel, from which it can be seen that the clamp fastening is also provided with a node point reinforcement 506.

[0110] Finally, Figure 15 shows a crank arm 600 of a pedal crank set for a bicycle, which crank arm is made in one piece from thermoplastic material and is at least partially additionally reinforced with a fiber fabric 601 made of long fibers. In the illustrated embodiment, the fiber reinforcement with long fibers forms, for example, the visible side of the crank arm 600, which may be desirable for aesthetic reasons. According to the invention, it can be provided that, for example, the passages for a bottom bracket axle or for receiving a thread for a pedal can also be reinforced, for example, with thermoplastic organic sheets in the form of overmolded, sleeve-shaped inserts.

[0111] List of reference symbols Bicycle frame Seat tube Seat stays Chain stays Down tube Mount for gearbox and / or motor Frame compartment Head tube Reinforcement profile 0 Frame compartment base 1 Feedthroughs 2 Flat structural reinforcement 3 Top tube 4 Node reinforcement 5 Head tube reinforcement 6 Rear triangle reinforcement 7 Interface reinforcement 8 Falling 9 Profile chamber A, B Reinforcement layers 1 Mounting base 00 Seat post 01 Unidirectional continuous fibers Reinforcement patch Fork Fork tube Fork crown Fork tube reinforcement Wheel Rim flank Spokes Hub body Handlebar Middle section of the handlebar Handlebar arm sections of the handlebar Grip ends of the handlebar Stem Unidirectional continuous fiber Node reinforcement of the stem Node reinforcement of the clamp attachment Crank arm Fiber scrim Crank arm

Claims

Claims 1. Structural component as a composite component for a vehicle, in particular for a bicycle, which was obtained by injection molding from a thermoplastic plastic preferably filled with tensile short fibers, wherein the structural component comprises at least in at least one partial area a further fiber reinforcement, wherein the further fiber reinforcement comprises tensile long fibers, wherein the tensile long fibers have been overmolded or injection-molded with the filled thermoplastic plastic as at least one insert in an injection mold, wherein the insert is selected from a group of inserts comprising strips of unidirectional, preferably continuous fibers, semipregs of fiber fabrics or fiber layups, prepregs of fiber layups or fiber fabrics or organic sheets as dimensionally stable semi-finished products with unidirectionally oriented or multidirectionally laid or woven tensile long fibers,and wherein at least some of the inserts comprise a thermoplastic material as a matrix material., 2. Structural component according to claim 1, characterized in that the insert part comprises a stocking-shaped or tubular fabric.

3. Structural component according to one of claims 1 or 2, characterized in that it is selected from a group of structural components comprising bicycle frames (1), frame parts, handlebars (500), seat posts (200), forks (300), handlebar stems, wheels (400), spokes, clamp fastenings, hub bodies (403), pedal cranks (600) and the like.

4. Structural component according to one of claims 1 to 3 as a profile or profile section of a bicycle frame 1, characterized in that the insert extends within the profile or the profile section over at least a partial cross-section of the profile or the profile section.

5. Structural component according to one of claims 1 to 4, characterized in that the insert part has a substantially at least partially closed cross-sectional contour, preferably in the form of a box-shaped or tubular hollow cross-section.

6. Structural component according to one of claims 1 to 5, characterized in that the structural component has a constant, defined wall thickness, in particular in the region of at least one cavity provided in the structural component.

7. Structural component according to one of claims 1 to 6, characterized in that it comprises at least one insert part designed as a fiber fabric or fiber scrim, which was overmolded or injection-molded as an insert part without a matrix material, such that the injection-molded filled thermoplastic material Fibre fabric or fibre fabric at least partially penetrates and / or encloses.

8. Structural component according to one of claims 1 to 7, characterized in that the insert is designed as a dimensionally stable semi-finished product with a thermoplastic matrix material.

9. Structural component as a profile or profile section of a bicycle frame 1 according to one of claims 1 to 8, characterized in that the insert part is arranged in a closed profile chamber 19 of the bicycle frame 1 or is integrated into a wall of the closed profile chamber 19 and / or at least partially encloses it, wherein the profile chamber 19 extends in the longitudinal direction of a frame profile and is preferably arranged within the frame profile in the region of an expected tensile stress during intended use of the bicycle frame 1.

10. Structural component according to claim 9, characterized in that the profile or the profile section forms a top tube 13 or a down tube 5 or a seat tube 2 of the bicycle frame 1 and the profile or the profile section has an open, preferably U-shaped cross-sectional profile forming a frame compartment 7 or at least partially enclosing a frame compartment 7.

11. Structural component according to one of claims 9 or 10, characterized in that the insert part forms a frame compartment 7 of the bicycle frame 1 and / or partially encloses it.

12. Structural component as handlebar 500 or seat post according to one of claims 1 to 7, comprising at least one overmolded or injection-molded continuous fiber-reinforced band with unidirectionally aligned, tensile-resistant long fibers as continuous fibers 505 as an insert.

13. Structural component according to one of claims 1 to 12, characterized in that the thermoplastic material filled with tensile short fibers has a filling level of 20 to 60 percent by weight based on the total weight of the structural component.

14. Structural component according to one of claims 1 to 13, characterized in that the tensile short fibers have a fiber length of 0.1 to 50 mm, preferably a fiber length of 0.1 to 1 mm.

15. Structural component according to one of claims 1 to 14, characterized in that the tensile long fibers have a fiber length greater than 50 mm.

16. Structural component according to one of claims 1 to 15, characterized in that the thermoplastic plastic and / or the thermoplastic matrix material is selected from a group of plastics comprising PA, PP, PPA, PS, PE, PE, ABS, PC, POM, PEK, PEEK, PA610, HPPA, PARA, PBT, PK.

17. Structural component according to one of claims 1 to 16, characterized in that the tensile long fibers are selected from a group of fibers comprising carbon fibers, glass fibers, aramid fibers, Kevlar fibers and basalt fibers. 18 . A method for producing a structural component made of thermoplastic material having the features of one of the preceding claims 1 to 17, the method comprising the following method steps: Providing an injection molding arrangement with at least one injection unit with means for plasticizing and providing a plasticized filled plastic under pressure into a tool with at least one cavity, and the at least one cavity at least partially defines the shape of the structural component and has at least one sprue, Inserting and fixing at least one insert part into at least one partial cavity of the tool, wherein the insert part is selected from a group of insert parts comprising strips of unidirectional, preferably endless fibers, semipregs of fiber fabrics or fiber layups, prepregs of fiber layups or fiber fabrics or organic sheets as dimensionally stable semi-finished products with unidirectionally oriented or multidirectionally laid or woven tensile long fibers, and wherein at least some of the insert parts comprise a thermoplastic as matrix material, Injecting the plasticized plastic under pressure into the closed tool and Opening the tool and removing the finished product. 19 . Method according to claim 18 , characterized in that as thermoplastic material at least one thermoplastic material filled with tensile short fibers is used.

20. The method according to claim 19, characterized in that the thermoplastic material filled with tensile short fibers has a filling level of 20 to 60 percent by weight based on the total weight of the structural component.

21. Method according to one of claims 18 to 20, characterized in that the tensile short fibers have a fiber length of 0.1 to 50 mm, preferably a fiber length of 0.1 to 1 mm.

22. Method according to one of claims 18 to 21, characterized in that the tensile long fibers have a fiber length greater than 50 mm.

23. Method according to one of claims 18 to 22, characterized in that the thermoplastic plastic and / or the thermoplastic matrix material is selected from a group of plastics comprising PA, PP, PPA, PS, PE, PE, ABS, PC, POM, PEK, PEEK, PA610, HPPA, PARA, PBT, PK.

24. Method according to one of claims 18 to 23, characterized in that the tensile long fibers are selected from a group of fibers comprising carbon fibers, glass fibers, aramid fibers, Kevlar fibers and basalt fibers.

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