Wheel bearing unit

Abstract

A hybrid connection element, in particular a bearing outer element of a wheel bearing, includes a core part made of steel and a reinforcement part made of plastic. The reinforcement part at least partially encases the core part. The core part includes a hollow cylindrical bearing unit extending in an axial direction and a flange extending in a radial direction. The reinforcement part includes at least one reinforcement rib which transmits force between the bearing unit and the flange of the core part.

Claims

1. A hybrid connection element, in particular a bearing outer element of a wheel bearing for securing a vehicle wheel, having a core part made of a first material, and a reinforcement part made of a second material, which at least partly encases and thus reinforces the core part, wherein the core part comprises a hollow cylindrical bearing unit for forming a rolling bearing, which extends in an axial direction, wherein the core part comprises a flange, which extends in a radial direction from one axial end of the bearing unit, wherein the reinforcement part comprises at least one reinforcement rib, which transmits forces between the bearing unit and the flange of the core part, wherein the at least one reinforcement rib comprises two reinforcing ribs that bridge a weight-reduction aperture in the flange in the radial direction in order to transmit forces across the aperture by means of the reinforcement part, and wherein the at least one reinforcement rib is of hollow design in order to save weight.

2. The hybrid connection element of claim 1, wherein the at least one reinforcement rib comprises a first end and a second end, wherein the first end is arranged on the bearing unit and is offset in the axial direction relative to the flange, wherein the second end is arranged on the flange and is offset outward in the radial direction from the bearing unit.

3. The hybrid connection element of claim 1, wherein the at least one reinforcement rib further comprises two additional reinforcement ribs, which tangentially adjoin the weight reduction aperture or a fastening socket in the flange.

4. The hybrid connection element of claim 1, wherein, in the radial direction, the height of the at least one reinforcement rib is greater on the inside at the bearing unit than the radially outer outside of the flange.

5. The hybrid connection element of claim 1, wherein each reinforcement rib is shaped as a region of the reinforcement part which is designed as a peak, wherein the transition from one reinforcement rib to another reinforcement rib runs via a region of the reinforcement part designed as a trough.

6. The hybrid connection element of claim 1, wherein the flange is in the form of a circular ring, wherein the flange comprises a connecting passage designed as a through hole in the axial direction in order to improve force transmission by the first material of the core part and the second material of the reinforcement part.

7. The hybrid connection element of claim 1, wherein the flange comprises at least one fastening socket for fastening a wheel rim of a vehicle, wherein the at least one fastening socket has a thread for a rim screw, wherein at least two reinforcement ribs are arranged at each fastening socket in tangential contact.

8. The hybrid connection element of claim 1, wherein the hollow cylindrical bearing unit comprises at least one rolling element race on the inner lateral surface, wherein the hollow cylindrical bearing unit comprises, on the outer lateral surface, a surface structure which comprises an enlarged surface for improved connection to the second material, thereby ensuring improved force transmission between the core part and the reinforcement part, wherein the flange comprises, at least on the surface oriented toward the bearing unit, a surface structure which comprises an enlarged surface for improved connection to the second material, thereby making it possible to ensure improved force transmission between the core part and the reinforcement part.

9. The hybrid connection element of claim 1, wherein the reinforcement part comprises a socket, in particular for a vehicle rim, wherein the socket extends the bearing unit of the core part in the axial direction, wherein the socket extends the bearing unit of the core part in the axial direction at the axial end of the bearing unit at which the flange is arranged.

10. The hybrid connection element of claim 1, wherein the core part and the flange are formed integrally and from the first material, wherein the core part and the flange are embodied as a forging, wherein the first material has a higher density than the second material, thereby making it possible to reduce the weight of the hybrid connection element, wherein the second material is a fiber reinforced thermoset plastic, wherein the thermal expansion coefficient of the first material differs from the thermal expansion coefficient of the second material by +/−10%.

11. A hybrid bearing outer element of a wheel bearing comprising: a core part, made of a first material, having a hollow cylindrical bearing unit which extends in an axial direction and a flange which extends in a radial direction from one axial end of the bearing unit; and a reinforcement part made of a second material, at least partially encasing the core part and having multiple hollow reinforcing ribs extending across a weight reduction aperture of the core part in the radial direction.

12. The hybrid bearing outer element of claim 11, wherein the multiple hollow reinforcing ribs comprise two hollow reinforcement ribs per weight reduction aperture in the flange.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The connection element is explained in greater detail below by means of an illustrative embodiment in conjunction with associated drawings. In these schematic drawings:

(2) FIG. 1 shows a sectional view of a hybrid connection element;

(3) FIG. 2 shows another sectional view of a hybrid connection element;

(4) FIG. 3 shows a three-dimensional view of a core part of the hybrid connection element from FIGS. 1 and 2;

(5) FIG. 4 shows a three-dimensional view of the hybrid connection element from FIGS. 1 and 2; and

(6) FIG. 5 shows a three-dimensional partial view of the hybrid connection element from FIGS. 1 to 4.

DETAILED DESCRIPTION

(7) In the description below, identical reference signs are used for identical objects.

(8) FIG. 1 shows a sectional view of a hybrid connection element 1.

(9) To be more precise, FIG. 1 shows a hybrid connection element, in particular a bearing outer element 1 of a wheel bearing for securing a vehicle wheel, having a core part 2 made of a first material, and a reinforcement part 3 made of a second material.

(10) The reinforcement part 3 at least partially encases the core part 2 and thus reinforces the latter. This state of affairs is illustrated even better in the other figures.

(11) In this case, the core part 2 has a hollow cylindrical bearing unit 4 for forming a rolling bearing, which extends in the axial direction A.

(12) In this arrangement, the hollow cylindrical bearing unit 4 has rolling element races on the inner lateral surface to form a rolling bearing.

(13) The core part 2 comprises a flange 5, which extends in the radial direction R from one axial end of the bearing unit 4.

(14) The reinforcement part 3 furthermore comprises various reinforcement ribs 6, which transmit forces between the bearing unit 4 and the flange 5 of the core part 2.

(15) Each reinforcement rib 6 has a shape which is designed or adapted to match the flow of force between the flange 5 and the bearing unit 4, wherein each reinforcement rib 6 has a first end 7 and a second end 8.

(16) In this case, the first end 7 is arranged on the bearing unit 4 and is offset in the axial direction A relative to the flange 5, wherein the second end 8 is arranged on the flange 5 and is offset outward in the radial direction R from the bearing unit 4.

(17) FIG. 1, but also FIG. 2, furthermore shows that the height of each reinforcement rib 6 decreases in the radial direction R from the inside at the bearing unit 4 to the outside, toward the flange 5.

(18) In other words, in the radial direction R, the height of each reinforcement rib 6 is greater on the inside at the bearing unit 4 than the radially outer outside of the flange 5.

(19) Although not apparent in the figures, the hollow cylindrical bearing unit 4 nevertheless has, on the outer lateral surface, a surface structure which comprises an enlarged surface for improved connection to the second material. This makes it possible to ensure improved force transmission between the core part 2 and the reinforcement part 3.

(20) The flange 5 also has, at least on the surface oriented toward the bearing unit 4, a surface structure which comprises an enlarged surface for improved connection to the second material. This likewise makes it possible to ensure improved force transmission between the core part 2 and the reinforcement part 3.

(21) As FIG. 1 also shows, the core part 2 has a socket 11 for a vehicle rim, wherein the socket 11 extends the bearing unit 4 of the core part 2 in the axial direction A.

(22) In this case, the socket 11 extends the bearing unit 4 of the core part 2 in the axial direction A at the axial end of the bearing unit 4 at which the flange 5 is arranged.

(23) As all the figures furthermore show, the core part 2 and the flange 5 are formed integrally and from the first material, wherein the core part 2 and the flange 5 are embodied as a steel forging.

(24) According to the illustrative embodiment illustrated, the first material has a higher density than the second material, thereby making it possible to reduce the weight of the hybrid connection element 1.

(25) The second material is a plastic or a fiber reinforced thermoset, wherein the second material can be applied to the first material in an injection molding process or a compression molding process.

(26) The thermal expansion coefficient of the first material differs from the thermal expansion coefficient of the second material by +/−2%.

(27) FIG. 2 shows another sectional view of the hybrid connection element 1.

(28) As regards the further statements, attention is drawn to the explanations according to FIG. 1, which are likewise applicable here, in order to avoid unnecessary repetition.

(29) However, in addition to FIG. 1, FIG. 2 shows that the surface of each reinforcement rib 6 encloses an angle β of 55 degrees with the bearing unit 4, whereas the surface of each reinforcement rib 6 encloses an angle α of 90 degrees with the surface of the flange 5.

(30) FIG. 3 shows a three-dimensional view of a core part 2 of the hybrid connection element 1 from FIGS. 1 and 2, whereas FIG. 4 shows a three-dimensional view of the hybrid connection element 1 from FIGS. 1 and 2.

(31) FIG. 5 furthermore shows a three-dimensional partial view of the hybrid connection element 1 from FIGS. 1 to 4.

(32) As regards the further statements, attention is drawn to the explanations according to FIGS. 1 and 2, which are likewise applicable here, in order to avoid unnecessary repetition.

(33) For the sake of simplicity and to avoid repetition, FIGS. 3, 4 and 5 are described together below.

(34) As can be seen from FIGS. 3 to 5, two reinforcement ribs 6 in each case bridge a weight-reduction aperture 9 in the flange 5 in the radial direction R. As a result, it is possible to transmit forces across the aperture 9 by means of the reinforcement part 3 and to increase tilting stiffness.

(35) In this case, the two reinforcement ribs 6 per aperture 9 tangentially adjoin one aperture 9 in the flange 5.

(36) In the example under consideration, the reinforcement ribs 6 are designed as solid parts but it is also possible for one or more or all of the reinforcement ribs 6 to be of hollow design in order to further reduce the weight of the hybrid connection element.

(37) Considering, in particular, FIGS. 3 and 4, it can be seen that the shape of a reinforcement rib 6 is designed to flow smoothly into the shape of another reinforcement rib 6.

(38) Moreover, the shape of a reinforcement rib 6 is designed to flow smoothly into the shape of another reinforcement rib 6 at the respective end of the reinforcement rib 6—cf. FIG. 5.

(39) In this case, each reinforcement rib 6 is shaped as a region of the reinforcement part 3 which is designed as a peak, wherein a region of the reinforcement part 3 which is designed as a trough is arranged between two reinforcement ribs 6.

(40) In other words, the transition from one reinforcement rib 6 to another reinforcement rib 6 passes via a region designed as a trough, wherein the transition from a region designed as a peak to a region designed as a trough and vice versa is designed to flow smoothly.

(41) With the aid of an embodiment of the hybrid connection element 1 which is designed for mutual merging or fusion or smooth transitions, notch action effects can be avoided.

(42) As FIGS. 3 to 5 furthermore show, two reinforcement ribs 6 which are arranged around an aperture 9 or around a fastening socket 10 of the flange 5 are designed to flow smoothly in the circumferential direction U.

(43) FIG. 3 shows that the flange 5 is in the form of a circular ring, wherein the flange 5 comprises various apertures 9 in order to reduce the weight of the hybrid connection element 1.

(44) In this case, the apertures 9 are arranged in a manner uniformly distributed in the circumferential direction U, wherein each aperture 9 is designed as a slotted hole.

(45) The aperture 9 designed as a slotted hole has a kidney-shaped configuration, wherein each aperture 9 extends in the circumferential direction U and completely penetrates the flange 5 in the axial direction A.

(46) The flange 5 furthermore has apertures 12, which are arranged in a manner uniformly distributed in the circumferential direction U, wherein each aperture 12 is designed as a connecting passage 12.

(47) The aperture 12 acting as a connecting passage is designed as a through hole in the axial direction A in order to improve force transmission by the first material of the core part 2 and the second material of the reinforcement part 3.

(48) The flange 5 furthermore has various fastening sockets 10 for fastening a wheel rim of a vehicle, wherein each fastening socket 10 has a thread for a rim screw.

(49) Two reinforcement ribs 6 are also arranged in tangential contact at each fastening socket 10. In other words, the reinforcement ribs 6 fully “embrace” or “enclose” or “surround” each fastening socket 10.

(50) The figures are described once again below in a supplementary way.

(51) The design of the plastic component or reinforcement part 3 is obtained from a topology optimization and has struts or reinforcement ribs 6 around regions which have to be reinforced to a greater extent, e.g. threaded holes or fastening sockets 10 or between the threaded holes.

(52) In this case, the ribs or reinforcement ribs 6 between the threaded holes or fastening sockets 10 are optional and can vary or be completely omitted, depending on the rigidity requirement (cf. FIG. 2, for example).

(53) In the area around drill holes or fastening sockets 10 or other apertures 9 which coincide with load introduction regions, it is advisable for the struts or reinforcement ribs 6 to extend as close as possible to the fastening sockets 10.

(54) This furthermore means that the strut shape or the shape of the reinforcement ribs 6 hugs the aperture 9. Overall, a bionically inspired overall shape is obtained, which preferably approximately resembles the roots of a tree when used on round flanges 5.

(55) The angles at which the supporting struts or reinforcement ribs 6 emerge from the various force introduction surfaces have various optimum values, depending on the loading case.

(56) More specifically, angles in a range of from 35° to 55° (ideally 45°) may be mentioned here for the transmission of shear, and angles between 75° and 95° (ideally 90° angle) may be mentioned here for the transmission of normal forces.

(57) For mixed loads, values between the stated angles are recommended (FIG. 4).

(58) A good profile shape of a supporting strut or reinforcement rib 6 can be interpolated from the optimum angles at the edge points or ends 7, 8, thus ensuring that the profile shape has transitions which are smooth as possible between various angles. In the case of 90°-45°, therefore, a convex shape is obtained in the profile, for example.

(59) The configuration around drill holes or fastening sockets 10 corresponds to very organic shapes. The crucial point here is that the strut or reinforcement rib 6 hugs the upper edge of the drill hole or fastening socket 10, as is the fusion of the struts/reinforcement rib 6 on both sides of the hole in the lower region.

(60) The shape of two struts/reinforcement ribs 6 around a circular drill hole/fastening socket 10 subjected principally to compression, when viewed from the front for example, is as shown in FIG. 5 when the loading on the steel flange or flange 5 is applied over an area and is primarily normal.

LIST OF REFERENCE SIGNS

(61) 1 hybrid connection element 2 core part 3 reinforcement part 4 bearing unit 5 flange 6 reinforcement rib 7 first end 8 second end 9 aperture 10 fastening socket 11 socket 12 aperture A axial direction R radial direction α angle β angle