METHOD FOR PRODUCING A FRAME COMPONENT FOR A DOOR FRAME STRUCTURE OF AN AIRCRAFT, FRAME COMPONENT, AND DOOR FRAME STRUCTURE

Abstract

A method for producing a frame component for a door frame structure of an aircraft. A connecting zone is generated on a first and a second assembly surface of a connecting component in each case by generating a surface texture on the assembly surfaces, wherein the connecting component is formed from a metal material. The assembly surfaces of the connecting component are placed against a door frame member and against an attachment member, wherein the door frame member and the attachment member are each formed from a fiber-reinforced thermoplastics material. Furthermore, the connecting component and the door frame member are welded, and the connecting component and the attachment member are welded. A frame component and a door frame structure are also described.

Claims

1. A method for producing a frame component for a door frame structure of an aircraft, the method comprising: forming a first connecting zone on a first assembly surface of a connecting component by generating a surface texture of the first assembly surface, wherein the connecting component is formed from a metal material; forming a second connecting zone on a second assembly surface of the connecting component by generating a surface texture of the second assembly surface, wherein the second assembly surface extends transversely with respect to the first assembly surface; placing the first assembly surface of the connecting component against a door frame member which is formed from a fiber-reinforced thermoplastics material; welding the connecting component and the door frame member, wherein thermoplastics material of the door frame member ingresses into the first connecting zone of the connecting component; placing an attachment member against the second assembly surface of the connecting component, wherein the attachment member is formed from a fiber-reinforced thermoplastics material; and welding the connecting component and the attachment member, wherein thermoplastics material of the attachment member ingresses into the second connecting zone of the connecting component.

2. The method according to claim 1, wherein formation of the first connecting zone and of the second connecting zone of the connecting component is performed in each case by melting of the metal material on the first and on the second assembly surface by a laser beam or by electrochemical roughening of the first and of the second assembly surface.

3. The method according to claim 1, wherein welding of the connecting component to the door frame member and to the attachment member is performed in each case by laser welding, ultrasound welding or induction welding.

4. The method according to claim 1, wherein the first and the second connecting zone of the connecting component are each formed with a surface topography which has level differences of between 1 m and 8 m.

5. The method according to claim 1, further comprising: forming a third connecting zone on a third assembly surface of the connecting component by generating a surface texture of the third assembly surface, wherein the third assembly surface is arranged opposite the second assembly surface and is oriented so as to face the latter, such that the second and the third assembly surface form a receiving space; at the same time as the attachment member is placed against the second assembly surface of the connecting component, placing the attachment member against the third assembly surface of the connecting component by sliding the attachment member into the receiving space; and welding the connecting component and the attachment member both at the second and at the third assembly surface of the connecting component, wherein thermoplastics material of the attachment member ingresses into the second and the third connecting zone of the connecting component.

6. The method according to claim 1, wherein the first assembly surface of the connecting component is placed against an abutment region of a surface of the door frame member and the second assembly surface of the connecting component is placed against an abutment region of a surface of the attachment member, wherein the door frame member and the attachment member, in the respective abutment region, comprise thermoplastics material in a thickness range of between 1 m and 8 m from the surface.

7. The method according to claim 1, wherein the door frame member has a U-shaped or C-shaped cross section formed by a transverse web and two side webs, and wherein the first assembly surface of the connecting component is placed against an inner surface, which extends between the side webs, of a longitudinal web of the door frame member.

8. The method according to claim 7, wherein the connecting component is placed with the first assembly surface against the inner surface of the longitudinal web of the door frame member such that the second assembly surface of the connecting component extends transversely with respect to the side webs of the door frame member.

9. The method according to claim 1, wherein the fiber-reinforced thermoplastics material has polyether ether ketone, polyphenylene sulphide, polyethyleneimine as matrix material.

10. A frame component for a door frame structure of an aircraft, comprising: a door frame member comprising a fiber-reinforced thermoplastics material; a connecting component comprising a metal material, which is welded to an inner surface of the door frame member; and an attachment member comprising a fiber-reinforced thermoplastics material, which is welded to the connecting component.

11. The frame component according to claim 10, wherein the connecting component is formed as an L-shaped or T-shaped angle piece, and wherein the connecting component is fastened by a first assembly surface to the door frame member and by a second assembly surface to the attachment member.

12. The frame component according to claim 10, wherein the door frame member has a U-shaped or C-shaped cross section formed by a transverse web and two side webs, and wherein the connecting component is fastened to an inner surface, which extends between the side webs, of the transverse web of the door frame member.

13. The frame component according to claim 10, wherein the frame component additionally has a structure member comprising a fiber-reinforced thermoplastics material and a further connecting component comprising a metal material, which further connecting component is welded to an inner surface of the structure member and to an end section, situated opposite the door frame member, of the attachment member.

14. The frame component according to claim 10, wherein the frame component additionally has a door stopper which is arranged on an outer surface situated opposite the inner surface of the door frame member and which has an abutment lug which projects from the outer surface.

15. A door frame structure for an aircraft, comprising: a first frame component for a door frame structure of an aircraft, comprising: a door frame member comprising a fiber-reinforced thermoplastics material; a connecting component comprising a metal material, which is welded to an inner surface of the door frame member; and an attachment member comprising a fiber-reinforced thermoplastics material, which is welded to the connecting component; a second frame component for a door frame structure of an aircraft, comprising: a door frame member comprising a fiber-reinforced thermoplastics material; a connecting component comprising a metal material, which is welded to an inner surface of the door frame member; and an attachment member comprising a fiber-reinforced thermoplastics material, which is welded to the connecting component; a first transverse strut, which extends between the door frame member of the first frame component and the door frame member of the second frame component and which is fastened in each case to a first end section of the door frame member of the first frame component and to a first end section of the door frame member of the second frame component; and a second transverse strut, which extends between the door frame member of the first frame component and the door frame member of the second frame component and which is fastened in each case to a second end section of the door frame member of the first frame component and to a second end section of the door frame member of the second frame component.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] The disclosure herein will be discussed below with reference to the figures of the example drawings. In the figures:

[0041] FIG. 1 shows a schematic view of a door frame structure of an aircraft according to an exemplary embodiment of the disclosure herein in a plan view;

[0042] FIG. 2 shows a perspective view of a frame component for a door frame structure of an aircraft according to an exemplary embodiment of the disclosure herein;

[0043] FIG. 3 shows a cut-away perspective view of a door frame member of the frame component shown in FIG. 2;

[0044] FIG. 4 shows a cut-away perspective view of a frame component according to a further exemplary embodiment of the disclosure herein;

[0045] FIG. 5 shows a schematic sectional view of a connecting component of a frame component according to an exemplary embodiment of the disclosure herein;

[0046] FIG. 6 shows a schematic view of the formation of a second connecting zone on a connecting component, which is performed as a step of a method according to an exemplary embodiment of the disclosure herein;

[0047] FIG. 7 shows a detail view of the region denoted by the alphabetic character X in FIG. 6;

[0048] FIG. 8 shows a schematic view of the welding of a connecting component and of an attachment member, which is performed as a step of a method according to an exemplary embodiment of the disclosure herein;

[0049] FIG. 9 shows a detail view of a welded connection between a connecting component composed of or comprising metal material and a door frame member or an attachment member composed of or comprising a fiber-reinforced thermoplastics material; and

[0050] FIG. 10 shows a detail view of the region denoted by the alphabetic character Y in FIG. 9.

[0051] In the figures, the same reference designations are used to denote identical or functionally identical components, unless stated otherwise.

DETAILED DESCRIPTION

[0052] FIG. 1 shows, by way of example, a door frame structure 100 of an aircraft. The door frame structure 100 has a first frame component 1, 101, a second frame component 1, 102, a first transverse strut 103, and a second transverse strut 104. The first and the second frame component 101, 102 are arranged so as to be spaced apart from one another. The transverse struts 103, 104 extend in each case transversely with respect to the frame components 101, 102, or run between these. The first transverse strut 103 is fastened to a first end region 101A of the first frame component 101 and to a first end region 102A of the second frame component 102. The second transverse strut 104 is fastened to a second end region 101B of the first frame component 101 and to a second end region 102B of the second frame component 102, wherein the second end regions 101B, 102B are, in relation to a longitudinal extent L of the frame components, situated opposite the first end regions 101A, 102A. As is schematically shown in FIG. 1, the frame components 101, 102 and the transverse struts 103, 104 together border or define a door opening 105, which can be closed by a door, which has not been illustrated.

[0053] FIG. 2 shows a perspective view of one of the frame components 1 schematically shown in FIG. 1. FIG. 3 shows a cut-away perspective view of a door frame member 10 of the frame component 1 shown in FIG. 2, and FIG. 4 shows a further perspective view of the door frame member 10.

[0054] As shown in FIGS. 2 to 4, the frame component 1 has a door frame member 10, a connecting component 20, an attachment member 30, an optional structure member 50, and an optional further connecting component 40. Furthermore, the frame component 1 has one or more door stoppers or stop elements 60. In the case of the frame component 1 shown by way of example in FIGS. 1 and 2, a total of seven attachment members 30 are provided.

[0055] As is shown by way of example in FIG. 2, the door frame member 10 is formed as an elongate component, which may have in particular an arcuate or generally a curved longitudinal extent. The door frame member 10 may be designed in particular as a profile member. The door frame member 10 shown by way of example in FIGS. 2 to 4 has a U-shaped or C-shaped cross section. Here, the cross section is formed by a transverse web 11, a first side web 12 and a second side web 13. The side webs 12, 13 extend in this case along one another, in particular parallel to one another, and are connected by the transverse web 11. The door frame member 10 is formed from a fiber-reinforced thermoplastics material, which has for example polyether ether ketone, abbreviated to PEEK, polyphenylene sulphide, abbreviated to PPS, polyethyleneimine, abbreviated to PEI, or a similar thermoplastics material as matrix material M. Into the matrix material M there are embedded reinforcement fibers F, such as for example carbon, glass, ceramic, aramid, boron, mineral, natural or plastics fibers or mixtures of these.

[0056] FIG. 5 shows, by way of example, a sectional view of the connecting component 20, 50. The connecting component 20 generally has a first assembly surface 20a, a second assembly surface 20b and optionally a third assembly surface 20c. In general, the second assembly surface 20a extends transversely with respect to the first assembly surface 20b, whereby a corner or an angle is formed by the assembly surfaces 20a, 20b.

[0057] The connecting component 20 shown by way of example in FIG. 5 is formed as a T-shaped angle piece. The connecting component 20 has a first web 25, a second web 26 and an optional third web 27. The second and the third web 26, 27 extend transversely with respect to the first web 25 and are arranged spaced apart from one another in a central region of the first web 25 and are connected to the first web. The first assembly surface 20a is situated on the first web. The second and the third web 26, 27 are arranged on a rear surface 25b situated opposite the first assembly surface 20a and project from the rear surface. The second web 26 has the second assembly surface 20b, and the optional third web 27 has the third assembly surface 20c. As can be seen in FIG. 5, the second and the third assembly surface 20b, 20c are oriented so as to face toward one another and delimit or define a receiving space 24.

[0058] Instead of the T-shaped cross-sectional form shown by way of example in FIG. 5, the connecting component 20 may also have a L-shaped cross-sectional form (not illustrated). For this purpose, the second web 26 and the optional third web 27 are both arranged on one lateral end region 28 of the first web 25 (not illustrated).

[0059] The connecting component 20 is formed from a metal material such as for example titanium, a titanium alloy, aluminum, an aluminum alloy or a similar metal material.

[0060] As shown by way of example in FIGS. 1, 2 and 4, the attachment member 30 is, similarly to the door frame member 10, likewise formed as an elongate component, in particular in the form of a profile member. The attachment member 30 shown by way of example in FIGS. 1, 2 and 4 has a linear or straight longitudinal extent. It is however self-evidently also possible for the attachment member 30 to have a curved longitudinal extent (not shown). The attachment member 30 shown by way of example in FIGS. 2 and 4 has a U-shaped or C-shaped cross section. Here, the cross section is formed by a transverse web 31, a first side web 32 and a second side web 33. Here, the side webs 32, 33 extend along one another, in particular parallel to one another, and are connected by the transverse web 31. As shown by way of example in FIG. 4, the transverse web 31 may have a reduced width in a first end section 30A of the attachment member 30.

[0061] The attachment member 30 is formed from a fiber-reinforced thermoplastics material, which has for example polyether ether ketone, abbreviated to PEEK, polyphenylene sulphide, abbreviated to PPS, polyethyleneimine, abbreviated to PEI, or a similar thermoplastics material as matrix material M. Into the matrix material M there are embedded reinforcement fibers F, such as for example carbon, glass, ceramic, aramid, boron, mineral, natural or plastics fibers or mixtures of these.

[0062] As can be seen in FIG. 2, the structure member 40 is likewise formed as an elongate component, which optionally has an arcuate or generally a curved longitudinal extent. The structure member 40 may be designed in particular as a profile member. The structure member 40 shown by way of example in FIG. 2 has an approximately Z-shaped cross section, which is formed by a longitudinal web 41, a first side web 42, which projects from the longitudinal web 41 at a first end thereof transversely with respect to a first side, and a second side web 43, which projects from the longitudinal web 41 at a second end thereof transversely with respect to a second side. As shown by way of example in FIG. 2, provision may be made for the cross section of the structure member 40 to be assembled from two L-shaped profile segments, which overlap in the region of the longitudinal web 41.

[0063] The structure member 40 is formed from a fiber-reinforced thermoplastics material, which has for example polyether ether ketone, abbreviated to PEEK, polyphenylene sulphide, abbreviated to PPS, polyethyleneimine, abbreviated to PEI, or a similar thermoplastics material as matrix material M. Into the matrix material M there are embedded reinforcement fibers F, such as for example carbon, glass, ceramic, aramid, boron, mineral, natural or plastics fibers or mixtures of these.

[0064] As shown in particular in FIG. 3, the optional door stopper 60 generally has a abutment lug 62. The latter is provided as a support or abutment surface for a door (not shown) of an aircraft. As illustrated by way of example in FIG. 3, the door stopper 60 may have a base plate 61, from which the abutment lug 62 projects. The door stopper 60 is formed generally from a metal material, such as for example titanium, a titanium alloy, aluminum, an aluminum alloy or the like.

[0065] As shown in particular in FIG. 4, an inner surface 10a of the door frame member 10 and the connecting component 20 are fastened to one another, in particular welded to one another. Furthermore, the connecting component 20 and the attachment member 30 are fastened to one another, in particular welded to one another. In particular, here, the first assembly surface 20a of the connecting component 20 lies against the inner surface 10a of the door frame member 10. For example, the first assembly surface 20a may bear against, or be welded to, a part of the inner surface 10a of the door frame member 10, the part being formed by an inner surface 11a , extending between the side webs 12, 13, of the first web 11 of the door frame member 10. As is also shown in FIG. 4, the second assembly surface 20b provided on the second web 26 of the connecting component 20 lies against a first surface 30a of the attachment member 30, in particular against the transverse web 31 of the attachment member 30.

[0066] If, in FIG. 4, a connecting component 20 with an optional third web 27 is used, a second surface 30b, situated opposite the first surface 30a, of the attachment member 30 lies against the optional third assembly surface 30c of the connecting component 20.

[0067] As is also shown in FIG. 4, the connecting component 20 may in particular be positioned relative to the door frame member 10, or fastened with the first assembly surface 20a to the inner surface 11a of the longitudinal web 11 of the door frame member 10, such that the second assembly surface 20b of the connecting component extends transversely with respect to the side webs 12, 13 of the door frame member 10. In particular, provision may thus be made for the second web 26 and possibly the optional third web 26 to run along a direction extending from the first longitudinal web 12 in the direction of the second longitudinal web 13 of the door frame member. This offers the advantage in particular that the first end section 30A of the attachment member 30 can be slid in between the first and the second web 12, 13 of the door frame member 10.

[0068] As shown in FIGS. 1 and 2, the attachment member 30 extends between the door frame member 10 and the optional structure member 40. The structure member 40 and the door frame member 10 extend along one another, preferably parallel to one another. A second end section 30B of the attachment member 30, situated opposite the first end section 30A in relation to the longitudinal extent of the attachment member 30, is fastened, in particular welded, to a second assembly surface 20b of the further connecting component 50. The second end section 30B of the attachment member 30 is possibly also fastened, in particular welded, to an optional third assembly surface 20c of the further connecting component 50. The further connecting component 50 is of identical construction to the connecting component 20 described on the basis of FIG. 5. The first assembly surface 20a of the further connecting component 20 lies against the inner surface 40a of the structure member 40 and is fastened, in particular welded, thereto.

[0069] As is also shown in FIG. 2, the connecting component 50 may in particular be positioned relative to the structure member 40, or fastened with the assembly surface 20a to the inner surface 40a of the structure member 40, such that the second assembly surface 20b of the connecting component extends transversely with respect to the side webs 42, 43 of the structure member 40.

[0070] As shown by way of example in FIGS. 1 and 2, it is possible for multiple attachment members 30 to be provided, which are each connected in the above-described manner to the door frame member 10 and possibly to the optional structure member 40. As is also shown in FIGS. 1 and 2, the individual attachment members 30 are arranged spaced apart from one another along the longitudinal extent L of the door frame member 10. In this way, a mechanically robust, ladder-like structure of the frame component 1 is formed.

[0071] As can be seen in particular in FIG. 3, the door stopper 60 is arranged on an outer surface 10b, situated opposite the inner surface 10a, of the door frame member 10, wherein the abutment lug 62 projects in relation to the outer surface 10b of the door frame member 10. In particular, the door stopper 60 may be screwed to the door frame member 10, as is illustrated by way of example in FIG. 3. The door stopper 60 shown in FIG. 3 lies with its optional base plate 61 against the outer surface 10b of the door frame member 10 and has four recesses, through which there are lead screws 63 which extend through the door frame member 10, in particular through the transverse web 11 of the door frame member 10. Optionally, a door stopper 60 is arranged, in relation to the longitudinal extent of the door frame member 10, so as to overlap, in particular so as to fully overlap, the first assembly surface 20a of the connecting component 20. In this case, the screws 63 each also extend through the first web 25 of the connecting component 20.

[0072] A frame component 1 designed in the manner described above may be installed in particular to form a door frame structure 100, as shown by way of example in FIG. 1 and already briefly described in the introduction. The first transverse strut 103 extends between the door frame member 10 of the first frame component 1, 101 and the door frame member 10 of the second frame component 1, 102, wherein the first transverse strut 103 is fastened in each case to a first end section 10A of the door frame member 10 of the first frame component 1, 101 and to a first end section 10A of the door frame member 10 of the second frame component 1, 102. The second transverse strut 104 extends between the door frame member 10 of the first frame component 1, 101 and the door frame member 10 of the second frame component 1, 102, wherein the second transverse strut 104 is fastened in each case to a second end section 10b of the door frame member 10 of the first frame component 1, 101, the second end section being situated opposite the first end section 10A in relation to the longitudinal extent L of the door frame member 10, and to a second end section 10B of the door frame member 10 of the second frame component 1, 102, the second end section being situated opposite the first end section 10A in relation to the longitudinal extent L of the door frame member 10. As shown in FIG. 1, the door frame member 10 and the transverse struts 103, 104 together border the door opening 105 which, when the door frame structure 100 is installed in an aircraft (not shown), is provided for the loading and unloading of the aircraft or as a passenger entrance or passenger exit. The optional door stoppers 60 project in this case into the door opening 105.

[0073] A method for producing a frame component 1 for a door frame structure 100 for a door of an aircraft will be described below. In particular, the frame component 1 described above can be produced by this method. Reference is therefore made to the subjects shown in FIGS. 1 to 5.

[0074] In the method, a first connecting zone 21 is formed on the first assembly surface 20a of the connecting component 20 by generating a surface texture of the first assembly surface 20a. Furthermore, a second connecting zone 22 is formed on the second assembly surface 20b of the connecting component by generating a surface texture of the second assembly surface 20b, and it is possibly additionally the case that a third connecting zone 23 is formed on the third assembly surface 20c by generating a surface texture of the third assembly surface 20c.

[0075] During the formation of the respective connecting zone 21, 22, 23, the respective assembly surface 20a, 20b, 20c of the metal material of the connecting component 20 is roughened, that is to say provided with a surface topography which has cavities or indentations and elevations. This step is illustrated by way of example and schematically in FIG. 6. By a laser source 200, a laser beam B is generated which is directed onto the respective assembly surface 20a, 20b, 20c by an optical waveguide 201, for example in the form of light-conducting fibers, by an optical device 202, which focuses and/or directs the laser beam B and/or filters certain wavelength ranges of the laser radiation. In this way, the metal material of the connecting component 20 is melted in the region of the respective assembly surface 20a, 20b, 20c. After this laser processing, the metal material solidifies again. In this way, a roughened surface forms. As an alternative to this laser processing, the respective connecting zone 21, 22, 23 may also be realized by electrochemical roughening of the respective assembly surface 20a, 20b, 20c.

[0076] FIG. 7 schematically shows a detail view of the connecting zone 21, 22, 23 of the connecting component. It can be seen that, as a result of the roughening, elevations 21P, 22P, 23P and depressions 21V, 22V, 23V have formed over an area. The first, the second and possibly the optional third connecting zone 21, 22, 23 of the connecting component 20 may in particular each be formed with a surface topography which has level differences d21, d22, d23 of between 1 m and 8 m. Accordingly, the respective connecting zone has a thickness of between 1 m and 8 m. In particular, as a result of the roughening, indentations or cavities 21V, 22V, 23V are formed in the respective assembly surface 20a, 20b, 20c which have a depth of between 1 m and 8 m. These level differences d21, d22, d23 can be seen in FIG. 10, to which reference will also be made in detail below.

[0077] Furthermore, the method comprises placing the first assembly surface 20a of the connecting component 20 against the door frame member 10, in particular against the inner surface 10a of the door frame member 10, preferably against the inner surface 11a of the transverse web 11 of the door frame member 10, as shown by way of example in FIG. 4 and already described in detail above.

[0078] Furthermore, the attachment member 30 is placed against the second assembly surface 20b of the connecting component 20, and in particular, the first surface 30a in the region of the first end section 30A of the attachment member 30 is placed against the second assembly surface 20b, as has been described in detail above. Optionally, the first end section 30A of the attachment member 30 is slid into the receiving space 24 of the connecting component 20, which is situated between the second and the optional third connecting surface 20a, 20b, 20c, as described above.

[0079] Provision may optionally be made for the first assembly surface 20a of the connecting component 20 to be placed against an abutment region 15 of the inner surface 10a of the door frame member 10, for the second assembly surface 20b of the connecting component 20 to be placed against an abutment region 35 of the first surface 30a of the attachment member 30, and possibly for the third assembly surface 20c of the connecting component 20 to be placed against an abutment region of the second surface 30b of the attachment member 30. In this respective abutment region 15, 35, the door frame member 10 and the attachment member 30 are formed, in the respective abutment region 15, 35 in the edge region of the cross section, exclusively from thermoplastics matrix material M, and so as to be free from reinforcement fibers F, as can be seen in particular in FIG. 10, as will be discussed in detail further below. In particular, the door frame member 10 and the attachment member 30 are, at least in the abutment region 15, 35, formed from thermoplastics matrix material M in a thickness range d15, d35 of between 1 m and 8 m from the respective surface 10a, 30a, 30b.

[0080] For the fastening of the door frame member 10 and of the attachment member 30 to the connecting component, the connecting component 20 and the door frame member 10 are welded, and the connecting component 20 and the attachment member 30 are welded. In each case, a hybrid welded connection is formed between the metal material of the connecting component 20 and thermoplastics matrix material M of the attachment member 30 and of the door frame member 10, respectively.

[0081] The welding of the attachment member 30 to the connecting component 20 is schematically illustrated in FIG. 8. The welding of the door frame member 10 to the connecting component 20 is performed analogously. For the welding, the laser source 200 is used to generate a laser beam B, which, by the optical waveguide 201, and via the optical device 202, is directed onto the respective connecting zone 21, 22, 23 or onto the contact region between the attachment member 30 and the connecting component 20 or between the door frame member 10 and the connecting component 20. This may be realized both by directing the laser beam B onto a web 25, 26, 27 of the connecting component 20 and by directing the laser beam B onto the door frame member 11 or the attachment member 30. As a result of the introduction of energy by the laser beam B, thermoplastics matrix material M of the attachment member 30 or of the door frame member 10, respectively, is changed into a plastically deformable state, in particular melted. As a result, thermoplastics matrix material M ingresses into the respective connecting zone 21, 22, 23 of the connecting component 20, and solidifies there.

[0082] FIG. 8 shows, by way of example and schematically, a welding robot 300 which has the laser source 200, the optical waveguide 201, the optical device 202, a chassis 301 and a manipulator 302. The chassis 301 may have multiple drive wheels, as shown in FIG. 8, and enables the welding robot 300 to be moved on the ground. The laser source 200 and the manipulator 302 are each connected to the chassis 301. The manipulator 302 has multiple movement arms 303 which are movable relative to one another, wherein the optical device 202 is arranged on a final movement arm 303. In this way, the laser beam B can be directed in an automated manner onto different locations, which facilitates the production of the frame component 1.

[0083] In general, the same laser source 200 can be used for forming the connecting zones 21, 22, 23 of the connecting component 20 and for the welding. The different required characteristics of the laser beam B can be generated by different optical devices 201.

[0084] As an alternative to the described laser welding, the welding of the connecting component 20 to the door frame member 10 and to the attachment member 30 may also be performed by ultrasound welding or induction welding. In general, it is necessary for the connecting zone 21, 22, 23 to be supplied with an amount of energy sufficient to melt thermoplastics matrix material.

[0085] FIGS. 9 and 10 show, in each case in detail, a sectional view of a hybrid welded connection formed in this way between the attachment member 30 and the connecting component 20 or between the door frame member 10 and the connecting component 20, wherein FIG. 10 illustrates in detail the region denoted by the alphabetic character Y in FIG. 9. As can be seen in particular in FIG. 10, as a result of the melting of thermoplastics matrix material M in the region of the respective surface 10a, 30a, 30b, the matrix material M ingresses into the cavities 21V, 22V, 23V of the respective connecting zone 21, 22, 23 of the connecting component 20 and solidifies there. In this way, an at least partially positively locking connection is produced between the metal material of the connecting component 20 and thermoplastics material of the door frame member 10 or of the attachment member 30 respectively. The cavities 21V, 22V, 23V have, in part, undercuts, and/or extend in each case in different directions. This additionally increases the mechanical load-bearing capacity of the welded connection.

[0086] As can also be seen in FIG. 10, thermoplastics matrix material M may be melted in particular in a thickness range d15, d35 of between 1 m and 8 m. As shown in FIG. 10, no reinforcement fibers F are present in this thickness range. In this way, damage to, deformation of and dislocation of the reinforcement fibers F as a result of the welding process are prevented.

[0087] FIG. 10 also shows that the level differences d21, d22, d23 of the surface texture of the respective assembly surface 20a, 20b, 20c of the connecting component 20 may optionally likewise amount to between 1 m and 8 m. In particular, provision may be made for the level differences d21, d22, d23 of the surface texture of the respective assembly surface 20a, 20b, 20c of the connecting component 20 to lie in a range between 50 percent and 90 percent of the thickness range d15, d35 of the door frame member 10 or of the attachment member respectively.

[0088] Welding of the second end section 30B of the attachment member 30 and of the optional structure member 40 to the further connecting component 50 may be performed in the same way as described above for the first end section 30A of the attachment member 30 and the door frame member 50 to the connecting component 20.

[0089] Although the disclosure herein has been discussed by way of example above on the basis of exemplary embodiments, it is not restricted to these, but rather may be modified in a wide variety of ways. In particular, combinations of the above exemplary embodiments are also conceivable.

[0090] While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms comprise or comprising do not exclude other elements or steps, the terms a, an or one do not exclude a plural number, and the term or means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.

LIST OF REFERENCE DESIGNATIONS

[0091] 1 Frame component [0092] 10 Door frame member [0093] 10a Inner surface of the door frame member [0094] 10b Outer surface of the door frame member [0095] 10A First end section of the door frame member [0096] 10B Second end section of the door frame member [0097] 11 Transverse web of the door frame member [0098] 11a Inner surface of the transverse web [0099] 12 First side web of the door frame member [0100] 13 Second side web of the door frame member [0101] 15 Abutment region [0102] 20, 50 Connecting component [0103] 20a First assembly surface of the connecting component [0104] 20b Second assembly surface of the connecting component [0105] 20c Third assembly surface of the connecting component [0106] 21 First connecting zone [0107] 22 Second connecting zone [0108] 23 Third connecting zone [0109] 21P-23P Elevation [0110] 21V-23V Cavities [0111] 24 Receiving space [0112] 25 First web of the connecting component [0113] 25b Rear surface of the first web [0114] 26 Second web of the connecting component [0115] 27 Third web of the connecting component [0116] 28 Lateral end region of the first web [0117] 30 Attachment member [0118] 30a First surface of the attachment member [0119] 30A First end section of the attachment member [0120] 30B Second end section of the attachment member [0121] 30b Second surface of the attachment member [0122] 31 Transverse web of the attachment member [0123] 32 First side web of the attachment member [0124] 33 Second side web of the attachment member [0125] 35 Abutment region of the attachment member [0126] 40 Structure member [0127] 40a Inner surface of the structure member [0128] 41 Longitudinal web of the structure member [0129] 42 First side web of the structure member [0130] 43 Second side web of the structure member [0131] 60 Door stopper [0132] 62 Abutment lug [0133] 100 Door frame structure [0134] 101 First frame component [0135] 101A First end region of the first frame component [0136] 101B Second end region of the first frame component [0137] 102 Second frame component [0138] 102A First end region of the second frame component [0139] 102B Second end region of the second frame component [0140] 103 First transverse strut [0141] 104 Second transverse strut [0142] 105 Door opening [0143] 200 Laser source [0144] 201 Optical waveguide [0145] 202 Optical device [0146] 300 Welding robot [0147] 301 Chassis [0148] 302 Manipulator [0149] 303 Movement arms [0150] B Laser beam [0151] L Longitudinal direction [0152] M Matrix material [0153] F Reinforcement fibers [0154] X, Y Region [0155] d15 Thickness range of the door frame member [0156] d35 Thickness range of the attachment member [0157] d21-d23 Level differences in, in each case, the first, second and third connecting zone