Fiber-reinforced vehicle body

Abstract

A method produces a fiber-reinforced body component for a motor vehicle. The body component has at least one opening, in particular one door opening or one window opening. The method includes at least the following steps: providing the body component; applying a reinforcing element made of fiber composite material having reinforcing fibers embedded in a matrix, in order to stiffen the body component, the matrix being in an uncured state, and the reinforcing element being applied to an opening frame of the opening, which opening frame is formed by the body component.

Claims

1. A method for producing a fiber reinforced vehicle body component for a motor vehicle, wherein the fiber reinforced body component has a vehicle body component with at least one opening and a reinforcing element, the method comprising the steps of: a. providing the vehicle body component; b. applying the reinforcing element to an internal periphery of a frame defined by at least one opening formed by the vehicle body component, wherein the reinforcing element comprises fiber composite material with reinforcing fibers embedded in an uncured matrix such that the reinforcing element is shaped from a prepreg shape via the application of the reinforcing element to the frame; c. curing the matrix of the reinforcing element applied to the frame such that the reinforcing element stiffens the vehicle body component.

2. The method according to claim 1, wherein the at least one opening is a door or window opening.

3. The method according to claim 1, wherein the step of applying the reinforcing element comprises: applying the reinforcing element to the frame in sections so as to extend around the opening.

4. The method according to claim 1, wherein the step of applying the reinforcing element comprises: applying the reinforcing element to: (i) an inner side of the frame, which inner side faces the opening, and/or (ii) an end face of the frame, which end face is on an outer side and/or inner side of the vehicle.

5. The method according to claim 1, wherein before or after the step of applying the reinforcing element, the method comprises: coating a surface of the vehicle body component with a corrosion protection layer.

6. The method according to claim 5, wherein the step of coating is a cathodic dip coating.

7. The method according to claim 5, wherein the step of coating comprises at least partial or complete curing of the corrosion protection layer, which curing takes place before the step of applying the reinforcing element.

8. The method according to claim 5, wherein following the step of applying the reinforcing element, a step of common curing of the corrosion protection layer and of the reinforcing element takes place.

9. The method according to claim 5, wherein the step of applying the reinforcing element comprises: direct laying of the reinforcing element onto the vehicle body component or the corrosion protection layer.

10. The method according to claim 1, wherein the fiber composite material of the reinforcing element comprises a fiber/plastic composite with reinforcing fibers which are embedded in a matrix, the reinforcing fibers being selected from a group comprising: glass fibers, carbon fibers, aramid fibers, plastic fibers, metal fibers and natural fibers.

11. The method according to claim 10, wherein the reinforcing fibers are configured as woven fabric, contexture, mesh, knitted fabric, unidirectional tapes, belts or rovings.

12. The method according to claim 1, wherein the step of applying the reinforcing element comprises: common applying of the matrix and the reinforcing fibers, or separate applying of the matrix and the reinforcing fibers in a number of part steps.

13. The method according to claim 1, wherein the step of applying the reinforcing element takes place by way of an “Automated Fiber Placement” method, a “Fiber Patch Placement” method, an “Automated Tape Laying” method, or by hand lay-up.

14. The method according to claim 1, wherein the reinforcing element is arranged along a force flow path.

15. The method according to claim 1, wherein the vehicle body component is manufactured at least in sections from a metallic material or from a plastic and/or a fiber reinforced plastic.

16. A vehicle, comprising: a fiber reinforced vehicle body component with at least one door opening or window opening defining a frame thereof; and a reinforcing element made from fiber composite material applied to an internal periphery of the frame, wherein the reinforcing element comprises fiber composite material with reinforcing fibers embedded in an uncured matrix such that the reinforcing element is shaped from a prepreg shape via the application of the reinforcing element to the frame, and such that the reinforcing element stiffens the vehicle body component when cured.

17. The vehicle according to claim 16, wherein the vehicle body component is produced by: a. providing the vehicle body component; b. applying the reinforcing element to the internal periphery of the frame formed by the vehicle body component so as to shape the reinforcing element from the prepreg shape via the application of the reinforcing element to the frame; and c. curing the matrix of the reinforcing element applied to the frame such that the reinforcing element stiffens the vehicle body component.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a flow chart of a method in accordance with the description.

(2) FIG. 2 is a perspective view of a fiber reinforced vehicle body component in accordance with the description.

DETAILED DESCRIPTION OF THE DRAWINGS

(3) FIG. 1 shows a flow chart with respect to a method for producing a fiber reinforced vehicle body component for a motor vehicle, the vehicle body component having at least one opening, in particular a door opening or a window opening. In accordance with the embodiment which is shown, the method comprises the following steps:

(4) step a.: providing of the vehicle body component,

(5) step b.: coating of a surface of the vehicle body component with a corrosion protection layer (optional step),

(6) step c.: applying of a reinforcing element made from fiber composite material with reinforcing fibers which are embedded in a matrix, the matrix having a non-cured state, and the reinforcing element being applied on an opening frame of the opening, which opening frame is formed by the (coated) vehicle body component.

(7) Here, step b is to be understood to be merely optional. Step b of coating can likewise be dispensed with at this point, and the reinforcing element can be applied to an uncoated vehicle body component.

(8) In every case, it is possible that the step of applying of the reinforcing element comprises applying of the reinforcing element to the opening frame merely in sections or so as to extend around the opening.

(9) Moreover, the step of applying can comprise applying of the reinforcing element to an inner side of the opening frame, which inner side faces the opening, and/or to an end face of the opening frame, which end face is on the outer side of the vehicle and/or the inner side of the vehicle.

(10) The fiber composite material of the reinforcing element can preferably comprise a fiber/plastic composite with reinforcing fibers which are embedded in a matrix, the reinforcing fibers being selected from a group comprising glass fibers, carbon fibers, aramid fibers, plastic fibers, metal fibers and/or natural fibers. To this end, the reinforcing fibers can be configured as woven fabric, contexture, mesh, knitted fabric, unidirectional tapes, belts or rovings.

(11) The optional step b. of coating can take place, for example, as coating of the surface with a cathodic dip coating (CDC). In accordance with an embodiment which is not shown, instead of before the applying of the reinforcing element, this can take place temporally after the applying.

(12) Furthermore, the optional step b. of coating can comprise an additional intermediate step b1., likewise merely optional in this regard, of at least partial or complete curing of the corrosion protection layer, which step takes place before step c. of the applying of the reinforcing element. If the additional step b1 is not carried out, the following applying of the reinforcing element takes place onto a non-cured corrosion protection layer.

(13) Step c. of the applying of the reinforcing element can preferably comprise direct laying of the reinforcing element onto the corrosion protection layer. If the optional step b. is not provided, the laying can in contrast take place directly onto the uncoated vehicle body component within the context of step c.

(14) At any rate, for example, step c. can comprise either common applying of the matrix and the reinforcing fibers, for example as a prepreg, or separate applying of the matrix and the reinforcing fibers, the separate applying taking place in a number of part steps c1, c2, . . . . For example, in a first part step, a matrix can first of all be applied, and the reinforcing fibers can subsequently be applied to the matrix. Accordingly, further layers of matrix and/or reinforcing fibers can subsequently be applied.

(15) It goes without saying that a plurality of layers can also be applied in part steps c1, c2, . . . which follow one another in the case of the common applying of the matrix and the reinforcing fibers.

(16) For example, step c. of applying of the reinforcing element can take place by way of the “Automated Fiber Placement” (AFP) method, the “Fiber Patch Placement” (FPP) method, the “Automated Tape Laying” (ATL) method or by means of hand lay-up. The reinforcing element can preferably be applied along a force flow path on the vehicle body component

(17) In accordance with the embodiment which is shown, a step d. of (common) curing of the reinforcing element and the corrosion protection layer can likewise optionally be provided following step c. If the reinforcing element has been applied to a corrosion protection layer which is not cured or is cured merely partially, common curing is brought about. If, in contrast, the reinforcing element has been applied to a corrosion protection layer which has already been cured, merely the reinforcing element is cured further in step d.

(18) Furthermore, in a following step e., a paint can optionally be applied to the reinforced vehicle body component, and the paint can be dried and/or cured.

(19) FIG. 2 shows a first embodiment of a fiber reinforced vehicle body component 10. This can be configured, for example, as part of a vehicle body or else, as shown in FIG. 2, as a vehicle body 10. This comprises a plurality of components 11a-11h which are connected fixedly to one another. A front end car frame 11a and an A-pillar 11b, a roof bow 11h, and a roof side frame 11c which is arranged as an extension to the A-pillar 11b and which merges at its rear end into a C-pillar 11d, are shown as components 11a-11h. The C-pillar 11d is connected to a trunk frame 11e. In addition, the roof side frame 11c is connected to an upper end of a B-pillar 11g which is fastened at a lower end to a side sill 11f.

(20) The vehicle body component 10 has a surface which is optionally coated with a corrosion protection layer. In addition, the fiber reinforced vehicle body component 10 has a plurality of openings 14a-14f in the form of four door openings 14a-d or a plurality of window openings 14e, 14f. A reinforcing element 13 (marked in gray) made from fiber composite material is applied in each case on an opening frame 15a-15d of the respective door opening 14a-14d, which opening frame 15a-15d is formed by the vehicle body component 10. The reinforcing element 13 is applied in each case peripherally on the respective opening frame 15a-15d. In particular, the reinforcing elements 13 are arranged on an inner side of the opening frame 15a-15d, which inner side faces the respective opening. As an alternative or in addition, the respective reinforcing element 13 can be provided on an end face of the opening frame 15a-15d, which end face is on the outer side of the vehicle and/or the inner side of the vehicle.

(21) The respective reinforcing element 13 made from fiber composite material is therefore arranged so as to span across components. Thus, a first reinforcing element 13 is arranged on a surface of the A-pillar 11b, the roof side frame 11c of the B-pillar 11g and the side sill 11f, which surface forms in each case the inner side of the opening frame at least in sections. For the rear door opening, the corresponding reinforcing element 13 is attached on a surface on the B-pillar 11g, the roof side frame 11c, the C-pillar 11d and the side sill 11f, which surface forms in each case the inner side of the opening frame at least in sections.

(22) Therefore, the respective reinforcing element 13 extends peripherally along a complete inner side of the respective door opening 14a-14d, and therefore ensures a particularly advantageous reinforcing and stiffening of the entire vehicle body.

(23) The fiber composite material of the respective reinforcing element 13 comprises a fiber/plastic composite with reinforcing fibers (merely indicated) which are embedded in a matrix, it being possible for the reinforcing fibers to be selected from a group comprising glass fibers, carbon fibers, aramid fibers, plastic fibers, metal fibers and/or natural fibers. For example, the reinforcing fibers of the first reinforcing element 13 can be configured as unidirectional tapes, belts or rovings. As an alternative or in addition, the reinforcing fibers of the first reinforcing element 13 can also, however, be provided as woven fabric, contexture, mesh or knitted fabric.