LOAD-BEARING STRUCTURE OF A MOTOR VEHICLE AND METHOD FOR PRODUCING THE SAME

Abstract

A load-bearing structure of a motor vehicle, having hollow profiles and junction elements to connect the hollow profiles. The hollow profiles may be fastened in receptacles of the junction elements, and the junction elements may have a plurality of areal webs in a vehicle vertical direction, at least some of the areal webs forming a framework structure which assists the load path in the respective junction element.

Claims

1-20. (canceled)

21. A load-bearing structure of a motor vehicle, comprising: hollow profiles, at least one of the hollow profiles being formed as an assembly of extruded profiles having a tube clamped and adhesively bonded between the assembly of extruded profiles; and junction elements to connect adjacent hollow profiles, the junction elements having receptacles to which are fastened the hollow profiles, a plurality of areal webs in a vehicle vertical direction, at least some of the areal webs forming a framework structure which assists the load path in a respective junction element, wherein at least one receptacle of at least one of the junction elements is formed in the vehicle vertical direction by the areal webs, and the areal webs that form the receptacle are formed as double walls arranged parallel and adjacent, on both sides, to at least one wall of the hollow profile fastened in the receptacle.

22. The load-bearing structure of claim 21, further comprising an adhesive between the areal webs.

23. The load-bearing structure of claim 21, further comprising a cover fastened to at least one of a top and a bottom of each junction element when viewed in the vehicle vertical direction.

24. The load-bearing structure of claim 21, further comprising a core arranged at least in one receptacle of one of the junction elements, the core having at least one delimiting surface which is arranged substantially parallel and adjacent, at an inside, to at least one wall of the hollow profile fastened in the receptacle.

25. The load-bearing structure of claim 24, wherein the core forms an inner termination of an adhesive bath.

26. The load-bearing structure of claim 24, wherein the core comprises a solid body composed of one of aluminum or a foamed material.

27. The load-bearing structure of claim 24, the core comprises a blow-moulded component to acoustically insulate the hollow profiles.

28. The load-bearing structure of claim 24, wherein the core comprises a solid body of a foam material which expands under in response to heat to acoustically insulate the hollow profiles.

29. The load-bearing structure of claim 24, wherein the core has a collar which is clamped into a respective junction element.

30. The load-bearing structure of claim 21, wherein at least one of the junction elements is assembled from at least two junction element parts.

31. The load-bearing structure of claim 30, wherein the junction element parts are fastened to one another by way of a dovetail connection.

32. The load-bearing structure of claim 21, wherein the hollow profiles comprise at least one of A-type pillars, B-type pillars, sills, transverse beams, front longitudinal beams and rear longitudinal beams.

33. The load-bearing structure of claim 21, wherein the junction elements comprise one of a fibre composite material, aluminum and steel.

34. The load-bearing structure of claim 21, wherein at least one of the hollow profiles is formed as an assembly of a plurality of tubes.

35. The load-bearing structure of claim 21, wherein at least one of the hollow profiles has a profile to receive a second hollow profile or junction element.

36. A load-bearing structure of a motor vehicle, comprising: hollow profiles, at least one of the hollow profiles being formed as an assembly of extruded profiles having a tube clamped and adhesively bonded between the assembly of extruded profiles; junction elements to connect adjacent hollow profiles, the junction elements having receptacles to which are fastened the hollow profiles, a plurality of areal webs in a vehicle vertical direction, at least some of the areal webs forming a framework structure which assists the load path in a respective junction element; and a core forming an inner termination of an adhesive bath, the core being arranged at least in one receptacle of one of the junction elements, the core having at least one delimiting surface which is arranged substantially parallel and adjacent, at an inside, to at least one wall of the hollow profile fastened in the receptacle.

37. A load-bearing structure of a motor vehicle, comprising: hollow profiles, at least one of the hollow profiles being formed as an assembly of extruded profiles having a tube clamped and adhesively bonded between the assembly of extruded profiles; junction elements to connect adjacent hollow profiles, the junction elements having receptacles to which are fastened the hollow profiles, a plurality of areal webs in a vehicle vertical direction, at least some of the areal webs forming a framework structure which assists the load path in a respective junction element; and a core arranged at least in one receptacle of one of the junction elements, the core having a collar which is clamped into a respective junction element, and at least one delimiting surface which is arranged substantially parallel and adjacent, at an inside, to at least one wall of the hollow profile fastened in the receptacle.

Description

DRAWINGS

[0031] Embodiments will be illustrated by way of example in the drawings and explained in the description below.

[0032] FIG. 1 illustrates a perspective view a junction element of a load-bearing structure, in accordance with embodiments.

[0033] FIGS. 2a to 2c illustrate a top view of the junction element of FIG. 1.

[0034] FIG. 3 illustrates the load-bearing structure of FIG. 2a, but with fastened hollow profiles.

[0035] FIG. 4 illustrates the junction element of FIG. 1, but with a cover.

[0036] FIG. 5 illustrates a top and side views of a load-bearing structure of a motor vehicle, in accordance with embodiments.

[0037] FIGS. 6a to 6c illustrate a top view of a connecting region of the load-bearing of FIG. 3.

[0038] FIGS. 7a and 7b illustrate perceptive and side views of the connecting region of FIG. 6.

[0039] FIGS. 8a and 8b illustrate top and side views of the junction element of FIG. 3.

[0040] FIGS. 9a and 9b illustrate side views of a connecting region between a hollow profile and a junction element, in accordance with embodiments.

[0041] FIGS. 10a to 10c illustrate side views of a connecting region between a hollow profile and a junction element, in accordance with embodiments.

[0042] FIGS. 11a and 11b illustrate perspective and plan views of a hollow profile suitable for receipt, in accordance with embodiments.

[0043] FIGS. 12a to 12d illustrate a method for arranging a further hollow profile (longitudinal profile) into a hollow profile (transverse profile), in accordance with embodiments.

[0044] FIGS. 13a and 13b illustrate perspective and plan views of a hollow profile as an assembly of multiple extruded profiles, in accordance with embodiments.

DESCRIPTION

[0045] As illustrated in FIG. 1, a junction element 2 of a load-bearing structure of a motor vehicle. The junction element 2 may be an extruded or impact-extruded or pultruded part, in each case having a plurality of areal webs 4 in a vehicle vertical direction z.

[0046] As illustrated in FIG. 3, some of the areal webs 4 may form a framework structure which assists the load path 5 in the junction element 2. In addition to the framework structure in the interior of the junction element 2, the areal webs 4 may also form the lateral delimitations of the junction element 2, and receptacles 3 for receiving hollow profiles 1. In a load-bearing structure of a motor vehicle, the illustrated junction element 2 may, for example, be used in structurally identical form as a left-hand and right-hand junction element in the load-bearing structure, produced using an identical extrusion die and handled in mirror-inverted form.

[0047] FIGS. 2a to 2c illustrate the junction element 2 of FIG. 1 in a two-dimensional section. The receptacles 3 may be formed by the areal webs 4 of the junction element 2. In each case two areal webs 4 may be designed to engage in parallel, and adjacently on both sides, around walls 6 of a hollow profile 1 fastened in the receptacles. In this regard, see also FIG. 6c.

[0048] As il FIG. 6c, between the parallel and adjacent areal webs 4 there is in each case one space which, for the fastening of the hollow profiles 1, may be filled with adhesive 7.

[0049] As illustrated in FIGS. 2b and 2c, the parallel and adjacent areal webs 4 may be realized in free-standing form already during the extrusion of the component (FIG. 2b), or else may initially be connected by a connecting web which is removed after the extrusion process (FIG. 2c). Better tolerance values at the joining point may be achieved through the retroactive removal of the connecting web.

[0050] As illustrated in FIG. 3, in the junction element 2, it is also the case that hollow profiles 1 have been inserted, and preferably adhesively bonded, into the receptacles 3 of the junction element 2. The areal webs 4 may be designed so as to assist the load path 5 in the junction element 2.

[0051] As illustrated in FIG. 4, junction elements 2 in accordance with embodiments may be used in a variety of forms, in particular for different positions within a load-bearing structure. Covers 8 may be fastened normally on the areal webs 4, on the top side and/or on the bottom side of the junction element as viewed in the vehicle vertical direction z, for example by way of so-called flow drilling through core holes of the extruded junction. The covers 8 also serve to close off the receptacles 3 for accommodating an adhesive bath for the fastening of the hollow profiles 1.

[0052] As illustrated in FIG. 5, a complete load-bearing structure of a motor vehicle has at the front and at the rear, right-hand and left-hand, junction elements 2 in each case may be used for the connection of hollow profiles 1. The hollow profiles 1 may be in this case a pair of A-type pillars 12, a pair of B-type pillars 13, a pair of sills 14, a pair of transverse beams 15, a pair of front longitudinal beams 16 and a pair of rear longitudinal beams 17. Here, the sills 14, transverse beams 15 and longitudinal beams 16, 17 may be arranged substantially in a plane, and the A-type pillars 12 and B-type pillars 13 may be arranged substantially perpendicular to said plane, as may be seen in particular in the side view at the top of FIG. 5.

[0053] As illustrated in FIGS. 6 and 7, the connection between the hollow profile 1 and junction element 2 is provided in more detail.

[0054] As illustrated in FIG. 6a, an adhesive bath may be injected into the receptacle 3 of the junction element 2.

[0055] As illustrated in FIGS. 6b and 6b, subsequently, the hollow profile 1 may be arranged or otherwise pushed into the receiving region such that, in the process, the adhesive 7 is displaced and the wall 6 of the fastened hollow profile 1 is wetted from both sides.

[0056] As illustrated in FIGS. 7a and 7b, from the escape of adhesive 7 from inspection bores 19, it may be identified whether the component has been adequately wetted and the adhesive connection is acceptable.

[0057] As illustrated in FIG. 8a, a junction element 2 may also be composed of a plurality of junction element parts 11. It may then be the case that each individual junction element part 11 has a framework structure in accordance with embodiments composed of areal webs 4 in order to assist the load path in the respective junction element part 11. Such a construction composed of a plurality of junction element parts 11 may be produced more easily and is easier to repair. The hollow profiles 1 may for example be a transverse beam 15 and a sill 14. The junction element parts 11 may be connected in a variety of conceivable ways, for example by way of adhesive bonding, screws, friction stir welding etc.

[0058] As illustrated in FIG. 8b, the junction element parts 11 may be connected to one another for example by way of a dovetail connection, in which adhesive 7 may be introduced into adhesive gaps, and the components may be held in position at least during the adhesive bonding process mechanically for example, by way of a fixing screw 20.

[0059] As illustrated in FIGS. 9a and 9b, for the adhesive bonding between a junction element 2 and a hollow profile 1, it may be expedient for additional side walls may be provided in order to provide further predefined spaces for an adhesive bath. The additional walls may be formed by a core 9 which is arranged substantially parallel and adjacent, at the inside, at least to one wall 6, ideally to all of the walls 6, of the hollow profile 1 fastened in the junction element. The core 9 may be arranged in the interior of the junction element 2 such that a receiving space for adhesive 7 and for one or more walls 6 of the hollow profile 1 may be fastened may be created between the core 9 and one or more areal webs 4. It may for example be provided that the core 9 is fixed by way of a centring screw 21 to the lower cover 8 of the junction element 2 only during the adhesive bonding process.

[0060] As illustrated in FIG. 10c, alternatively or in addition, the core 9 may also be designed so as to have a collar 10 which is clamped with a slight oversize into the junction element 2 or else into a base hollow profile. In this way, the side walls and the collar 10 of the core 9 again create a space for an adhesive filling, such that the hollow profile 1 may be fastened may be immersed in the adhesive bath. A bore 22 in the hollow profile 1 permits the passage of adhesive 7 for improved hold of the hollow profile 1.

[0061] Here, it is also an important function of the core 9 to form the inner termination of the adhesive bath. Furthermore, as a result of the hollow profile 1 or the wall 6 thereof being pressed into the junction element 2, the adhesive 7 swells up to or over the upper edge of the ends of the junction elements 2 owing to the core 9, whereby it is possible to inspect whether sufficient adhesive 7 has been provided and whether the adhesive 7 has also been distributed across the entire connecting surface.

[0062] As illustrated in FIGS. 11a and 11b, a hollow profile 1 (in each case on the left in the figures) is suitable for receipt of a second hollow profile 23.

[0063] As illustrated in FIGS. 12a to 12d, a second hollow profile 23 (longitudinal profile, on the right in the figures) may be received into the first hollow profile 1 (transverse profile).

[0064] As illustrated in FIG. 12a, structure adhesive 7 is initially applied to the first hollow profile 1. Spaced apart from said first hollow profile 1, a second hollow profile 23 is then moved along closer to the intended contact surface but without coming into contact with, and thus displacing, the adhesive 7.

[0065] As illustrated in FIG. 12c, the longitudinal profile 23 is, if necessary, set down on the contact surface (arrow direction) in order may be pushed into the groove of the transverse profile 1.

[0066] As illustrated in FIG. 12d, in addition to the adhesive 7, it is also possible to use screws, punch rivets and the like, for example, as connecting aids at the positions indicated by dashed lines.

[0067] As illustrated in FIGS. 13a and 13b, a hollow profile 1 in the form of an assembly of multiple extruded profiles is provided. Here, a stiffening tube 24 is clamped between an inner extruded profile 25 (inner A-type piller) and an outer extruded profile 26 (outer A-type piller). A front supporting beam 27 is connected to the extruded profile assembly.

[0068] The term coupled or connected may be used herein to refer to any type of relationship, direct or indirect, between the components in question, and may apply to electrical, mechanical, fluid, optical, electromagnetic, electromechanical or other connections. In addition, the terms first, second, etc. are used herein only to facilitate discussion, and carry no particular temporal or chronological significance unless otherwise indicated.

[0069] Those skilled in the art will appreciate from the foregoing description that the broad techniques of the embodiments may be implemented in a variety of forms. Therefore, while the embodiments have been described in connection with particular examples thereof, the true scope of the embodiments should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification, and following claims.

LIST OF REFERENCE SIGNS

[0070] 1 Hollow profile

[0071] 2 Junction element

[0072] 3 Receptacle

[0073] 4 Areal webs

[0074] 5 Load path

[0075] 6 One wall of the fastened hollow profile

[0076] 7 Adhesive

[0077] 8 Cover

[0078] 9 Core

[0079] 10 Collar

[0080] 11 Junction element part

[0081] 12 A-type piller

[0082] 13 B-type piller

[0083] 14 Sill

[0084] 15 Transverse beam

[0085] 16 Front longitudinal beam

[0086] 17 Rear longitudinal beam

[0087] 18 Roof

[0088] 19 Inspection bore

[0089] 20 Fixing screw

[0090] 21 Centring screw

[0091] 22 Bore

[0092] 23 Second hollow profile

[0093] 24 Stiffening tube

[0094] 25 Inner extruded profile

[0095] 26 Outer extruded profile

[0096] 27 Front supporting beam

[0097] x Vehicle longitudinal direction

[0098] y Vehicle transverse direction

[0099] z Vehicle vertical direction