Vehicle Structural Component, Modular System and Method for Producing Vehicle Structural Components

Abstract

A vehicle structural component includes a main body having a receptacle and a first insert for reinforcing the vehicle structural component. The insert is accommodated in the receptacle and only partially fills the latter. At least one further insert fits in the receptacle. A modular system for producing vehicle structural components and a method for producing vehicle structural components are provided.

Claims

1.-20. (canceled)

21. A vehicle structural component, comprising: a basic body having a receptacle; a first insert for stiffening the vehicle structural component, the first insert being accommodated in the receptacle and only partially filling the receptacle; and at least one further insert which fits in the receptacle.

22. The vehicle structural component according to claim 21, wherein the basic body is a fiber-reinforced plastics component.

23. The vehicle structural component according to claim 21, wherein the at least one first insert and/or the at least one further insert is made of a fiber-reinforced plastic.

24. The vehicle structural component according to claim 21, wherein the first and further inserts are in contact with one another along a longitudinal side.

25. The vehicle structural component according to claim 21, wherein the receptacle is formed by an elongate groove, and the first insert and the at least one further insert are bar-shaped, wherein a profile of the inserts corresponds to a profile of the elongate groove.

26. The vehicle structural component according to claim 21, wherein the first and further inserts inserted into the receptacle fill the receptacle.

27. The vehicle structural component according to claim 21, wherein the first insert is connected to the basic body by overmolding or by plastics welding.

28. The vehicle structural component according to claim 27, wherein the at least one further insert is connected to the basic body by plastics welding.

29. The vehicle structural component according to claim 21, wherein the first insert and/or the at least one further insert has a rectangular profile.

30. The vehicle structural component according to claim 21, wherein the first insert and the at least one further insert are identical components.

31. The vehicle structural component according to claim 21, wherein the vehicle structural component is a cowl.

32. A modular system for producing vehicle structural components, comprising: identically configured basic bodies, which have at least one receptacle; and a plurality of inserts, wherein the receptacle and the inserts are tailored to one another in their geometry such that optionally one or more inserts are insertable into the same receptacle.

33. The modular system according to claim 32, wherein the plurality of inserts completely fill the receptacle without projecting therefrom.

34. The modular system according to claim 32, wherein the basic bodies and the inserts are plastics components which are weldable to one another.

35. A method for producing vehicle structural components using a modular system, the method comprising: a) providing a basic body having at least one receptacle for an insert, and providing a first insert seated in the receptacle in order to produce a component; and b) inserting at least one further insert into the receptacle of the provided basic body, wherein the vehicle structural component is intended to have a higher strength than the component produced in step a).

36. The method according to claim 35, wherein the receptacle is closed by an outer skin which covers the receptacle.

37. The method according to claim 35, wherein after the first insert is connected to the basic body, the at least one further insert is likewise connected to the basic body.

38. The method according to claim 37, wherein after the receptacle has been closed and/or after the vehicle structural component has been painted, the at least one further insert is welded to the basic body.

39. The method according to claim 35, wherein the first insert is connected to the basic body by being inserted into a corresponding mold and overmolded during production of the basic body.

40. The method according to claim 35, wherein the basic body is produced by an additive manufacturing method and, after the basic body has been produced, the first insert is inserted into the receptacle and connected to the basic body.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] FIG. 1 shows part of an intermediate product during the production of a vehicle structural component according to an embodiment of the invention in a view from above.

[0032] FIG. 2 shows part of the intermediate product from FIG. 1 in a view from below.

[0033] FIG. 3 shows a cross section through the intermediate product from FIG. 1.

[0034] FIG. 4 shows part of an exemplary vehicle structural component according to the invention in a view from above.

[0035] FIG. 5 shows part of the exemplary vehicle structural component according to the invention in a view from above.

[0036] FIG. 6 shows a cross section through the exemplary vehicle structural component according to the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

[0037] FIGS. 1 to 3 each show a vehicle structural component 10, which represents an intermediate product 12 during the production of an exemplary vehicle structural component 14 (see FIG. 4) according to the invention. FIGS. 1 and 2 show part of the elongate vehicle structural component 10 in a respective view from above and from below. FIG. 3 shows a cross section through the vehicle structural component 10.

[0038] The intermediate product 12 itself is already a functional vehicle structural component 10, specifically a cowl for a motor vehicle.

[0039] As can be seen particularly well in particular in FIG. 3, the vehicle structural component 10 comprises a basic body 16 in which a plurality of receptacles 18 are present. The receptacles 18 are each formed by an elongate groove which has a rectangular profile and virtually completely extends or completely extends over the entire length of the vehicle structural component 10.

[0040] The basic body 16 is a plastics component, in particular consisting of a short-fiber-reinforced thermoplastic.

[0041] In the exemplary embodiment shown there are provided four receptacles 18, of which two receptacles 18 are arranged on an upper side and two receptacles 18 are arranged on a lower side of the vehicle structural component 10. The terms “upper side” and “lower side” relate here to an assembled state of the vehicle structural component 10 in a motor vehicle. However, the number of receptacles 18 can vary, depending on the type of the vehicle structural component 10.

[0042] In each of the receptacles 18 there is respectively arranged a first insert 20. For example, the first inserts 20 can be reliably connected to the basic body 16 by means of overmolding or plastics welding.

[0043] The inserts 20 are preferably fiber-reinforced and contain continuous fibers. The inserts 20 serve for stiffening the vehicle structural component 10 and, just like the receptacles 18, extend virtually completely or extend completely over the entire length of the vehicle structural component 10.

[0044] In the exemplary embodiment shown, the first inserts 20 are bar-shaped and have a rectangular profile. Contemplated, however, are also other profile shapes of the inserts 20, with the profiles of the inserts 20 and of the receptacles 18 being tailored to one another in such a way that no empty spaces result in the vehicle structural component 10. That is to say that the inserts 20 are adapted to the profile of the receptacles 18.

[0045] If a first insert 20 is arranged in a receptacle 18, it does not completely fill the latter, with the result that a receptacle remains for a further insert 24.

[0046] The vehicle structural component 14 illustrated in FIGS. 4 to 6 differs from the intermediate product 12 illustrated in FIGS. 1 to 3 by virtue of the fact that a further insert 24 is additionally seated in each receptacle 18. As a result of the further insert 24, a strength of the vehicle structural component 14, in particular a stiffness in the vehicle transverse direction, with respect to an assembled state of the vehicle structural component 14, is increased by comparison with the above-described vehicle structural component 10.

[0047] Consequently, the vehicle structural component 14 can be adapted to the respectively prevailing requirements as a result of the further insert 24 and can take up higher loads than a vehicle structural component 10 in which in each case only a first insert 20 is arranged in the receptacles 18.

[0048] The additional insert 24 is preferably welded to the basic body 16, in particular by means of plastics welding.

[0049] By means of the inserts 20, 24 together, the receptacle 18 is completely filled without the inserts 24 projecting from the receptacle. As a result, the inserts 24 extend along an upper side or a lower side of the vehicle structural component 14, that is to say along an outer surface of the vehicle structural component 10. In particular, part of the outer surface of the vehicle structural component 14 is formed by a surface of an insert 24.

[0050] The first inserts 20 and the further inserts 24 are preferably identical components having an identical cross section, as illustrated in FIG. 6. In this way, the inserts can equally be used as first inserts 20 or as further inserts 24.

[0051] In an assembled state, as shown in FIGS. 4 to 6, the inserts 20, 24 are in contact with one another along a longitudinal side.

[0052] To produce the vehicle structural component 14 according to the invention there is provided a modular system 26 according to the invention that has identically configured basic bodies 16 and a plurality of inserts 20, 24. The basic bodies 16 and the inserts 20, 24 of the modular system 26 correspond to the components shown in the figures. It is thus possible for the required number of inserts 20, 24 to be inserted into the basic body 16 during the production of the vehicle structural component 14 according to the invention.

[0053] In order to produce a vehicle structural component 14 according to the invention using the modular system 26, the following steps are carried out.

[0054] First of all, a basic body 16 having at least one receptacle 18 for an insert 20, 24 and also a first insert 20 seated in the receptacle 18 are provided.

[0055] The first insert 20 has been connected to the basic body 16 either in an injection-molding process for the production thereof by the insert 20 having been inserted into a mold and overmolded with plastic. Alternatively, the first insert 20 can be connected to the basic body 16 by means of plastics welding. In this case, the basic body 16 can have been produced either by means of injection-molding or by means of an additive manufacturing method, for example by means of 3D printing.

[0056] This intermediate product 12, which comprises the basic body 16 and in each case a first insert 20 per receptacle 18, but no further insert 24, corresponds to the vehicle structural component 10 which is illustrated in FIGS. 1 to 3 and which already satisfies the requirements of some vehicle models. In particular, the intermediate product 12 is distinguished by the fact that the receptacles 18 are not completely filled, that is to say that there is still space for at least one further insert 24 in the receptacle.

[0057] If, however, the vehicle structural component 14 is intended to have a higher strength than the vehicle structural component 10 produced in the preceding step, a further insert 24 is inserted into the receptacle 18.

[0058] The insertion of the at least one further insert 24 into the receptacle 18 occurs here at a later time in the manufacturing process than the insertion of the first insert 20, for example after a painting operation.

[0059] After the insertion of the further insert 24, the receptacle 18 can be closed by means of an outer skin (not shown), which covers the receptacle 18, or by means of a cladding component (not shown).

[0060] The welding of the at least one further insert 24 to the basic body 16 can occur before or after closing the receptacle 18 of the vehicle structural component 14.