WO2002055923A2 - Structural element reinforced with metal foam - Google Patents

Structural element reinforced with metal foam Download PDF

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Publication number
WO2002055923A2
WO2002055923A2 PCT/EP2001/014438 EP0114438W WO02055923A2 WO 2002055923 A2 WO2002055923 A2 WO 2002055923A2 EP 0114438 W EP0114438 W EP 0114438W WO 02055923 A2 WO02055923 A2 WO 02055923A2
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WO
WIPO (PCT)
Prior art keywords
structural element
hollow profile
metal foam
foam
cavity
Prior art date
Application number
PCT/EP2001/014438
Other languages
German (de)
French (fr)
Inventor
Jörg BURZER
Konrad Eipper
Ralf Jakob
Jörg Rossow
Original Assignee
Daimlerchrysler Ag
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Daimlerchrysler Ag filed Critical Daimlerchrysler Ag
Publication of WO2002055923A2 publication Critical patent/WO2002055923A2/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B62D29/002—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material a foamable synthetic material or metal being added in situ

Definitions

  • the invention relates to a structural element according to claim 1 and a method for producing a structural element according to claim ⁇ .
  • Lightweight structures are an important basis for reducing fuel consumption in traffic engineering, especially in automotive engineering. Lightweight structures can be realized through the choice of materials (e.g. aluminum) or through constructive measures (use of smaller wall thicknesses of steel structures in connection with struts) or through combinations of these measures.
  • DE 198 13 092 AI describes a structural element made of sheet steel, which is reinforced with an aluminum foam.
  • aluminum powder which is provided with a blowing agent, is filled into a hollow profile through an opening.
  • the aluminum powder is then foamed by a temperature treatment which is in the range of the melting point of aluminum.
  • the disadvantage of this invention is that the temperature for foaming must be chosen so high that the dimensional stability of the structural element is considerably impaired; aluminum as the shaping material of the structural element is out of the question in this invention.
  • contact corrosion is generated, which significantly reduces the service life of the structural component.
  • the object of the invention is therefore to provide a foam-reinforced structural element which, compared to the prior art, has a significantly reduced tendency to corrode, a higher rigidity and a higher dent resistance.
  • the object is achieved in a structural element according to claim 1 and in a method according to claim 6.
  • the structural element according to the invention has a hollow profile, which represents the outer shape of the structural element and forms a cavity.
  • a structural element can be used as a component and self-supporting.
  • the structural element is reinforced with a metal foam (foam element) which at least partially fills the cavity.
  • the structural element according to the invention also has a separating layer between the foam element and an inner surface of the hollow profile, which is made of an expanded material.
  • the expanded material is based on an expandable material that increases its volume during a temperature treatment and / or a chemical treatment. This can be an expansion adhesive or a swelling foam or a low melting metal foam. Foams based on polyurethane or epoxy are particularly suitable.
  • This separating layer prevents contact corrosion, which usually occurs when metals with different electrochemical potentials come into contact with one another.
  • Another advantage of the separating layer is that tolerances which can be compensated for in the manufacture of the hollow profile or the foam element, which are necessary for introducing the foam element into the cavity, can be compensated for by this layer.
  • This advantage of the 1 structural element according to the invention also comes into play when the hollow profile is made of a non-metallic material, such as. B. polyethylene or a composite material such. B. carbon fiber reinforced plastics (CFRP) is shown.
  • CFRP carbon fiber reinforced plastics
  • the separating layer according to the invention takes over force-transmitting functions between the foam element and the hollow profile of the structural element and thus contributes to increasing the body rigidity.
  • the thickness of the separating layer is generally between 0.5 mm and 15 mm, particularly preferably between 1 mm and 3 mm.
  • the hollow profile of the structural element according to the invention is formed by metal sheets. This offers advantages when introducing the foam element into the cavity, in particular if the hollow profile is made from two or more individual parts (partial profile). It is also possible to represent the hollow profile by means of extruded profiles or cast parts. In these cases, the cavity should be openly accessible on at least one side so that the foam element can be inserted into the cavity of the hollow profile (claim 2).
  • the forces that act on the structural element are aimed at preferred spatial directions. It is therefore expedient in the sense of the invention to fill the cavity with metal foam, in particular along these directions of force, so that these forces can be compensated for. This results in a further weight reduction with approximately the same stability of the structural element, and material costs are also saved since less metal foam is used (claim 4).
  • Metal foams based on aluminum and / or zinc have a high degree of energy absorption and are due to the relatively low melting temperature of this talle producible with comparatively little technical effort (claim 5).
  • Another object of the invention according to claim 6 is a method for producing a structural element which is formed by a hollow profile and is reinforced by a foam element.
  • the advantages mentioned for claims one to five also apply to the method according to claim 6.
  • the method according to the invention is characterized in that a foam element and / or a hollow profile, the shape of which is matched to one another, is provided with an expandable material. It is possible that the z. B. immerse foam element in a bath with liquid expandable material or to coat or spray it with the expandable material. It is necessary to adjust the viscosity of the expandable material to the requirements of the application techniques mentioned.
  • the foam element coated with expandable material is introduced into the cavity. It is necessary here that the hollow profile in this process step has a sufficiently large opening through which the foam element can be introduced and which is closed in the further course of the process. After this process step there is a defined scope between the foam element and the hollow profile. To avoid mutual displacement between the hollow profile and the foam element, it is expedient to mechanically, for. B. to fix by clamps or screws.
  • a multi-part hollow profile is particularly suitable for this, in which the individual parts are joined together by gluing, welding, riveting, folding or by detachable connections become.
  • the introduction of the foam element into a multi-part hollow profile considerably simplifies the process.
  • a heat treatment e.g. B. after the cathode dip painting which is necessary anyway in the course of the process for the production of body parts.
  • the expandable material expands and a non-positive connection is formed with the hollow profile, which also serves as a protection against corrosion between the hollow profile and the foam element.
  • Fig. 1 is a foam element in the form of a cuboid.
  • Fig. 2 is a foam element with an x-shaped cross section.
  • Fig. 3 shows a foam element from Fig. 1, partially provided with an expandable material.
  • FIG. 4 shows a structural element with a hollow profile and a cuboid foam element according to FIG. 1.
  • FIG. 5 shows a structural element with a hollow profile and a foam element according to FIG. 2.
  • Figures 1 and 2 each show an example of a foam element 2 and 2 ⁇ .
  • the foam element 2 from FIG. 1 is designed as a solid body and is adapted to the shape of the structural element.
  • the cuboid representation is exemplary; the foam element could also be adapted to the structural element in a curved and / or rounded shape.
  • FIG. 2 shows a foam element 2 X which partially fills the structural element, in particular in the direction of the essential loads.
  • the foam element is designed with an x-shaped cross section. The angles of the x are to be adapted to the requirements of the structural component.
  • others e.g. B. T-shaped, O-shaped, L-shaped or more complex cross sections conceivable.
  • FIG. 3 shows the foam element 2, which in this case is partially provided with an expandable material 4.
  • the expandable material 4 is applied in such a way that contact between a hollow profile 6 of the structural element 1 and a foam element 2 is avoided.
  • FIGS. 4 and 5 show examples of a structural element, on the one hand with a full foam filling (FIG. 4) or with a partial foam filling with an x-shaped cross section (FIG. 5). Both structural elements have a separating layer 7 according to the invention between the hollow profile 6 and the foam element 5.
  • the hollow profile 6 of the structural element from FIGS. 5 and 6 is formed in one piece and spot welded to a seam 8. It is also possible to design the surface ⁇ of the structural element 1 in several parts, in particular in the form of two half-shells.
  • the structural component is preferably designed as a body part in an automobile. It can perform load-bearing functions in the floor assembly (e.g. as a sill, longitudinal or cross member of the engine) or can be used as an A, B or C pillar in the body structure.
  • the shape of the structural element is therefore adapted to the design-related requirements.
  • structural elements according to the invention can be used in the chassis area and in engines.
  • the seam 8 is shown only schematically in FIGS. 4 and 5.
  • All in the manufacture of Structural components usual joining methods are used, this applies in particular to the folding, welding, gluing, soldering, screwing or riveting.
  • An aluminum-based foam element (alloy A1SÜ2), which has a porosity of 70% and thus a density of 0.81 g / cm 3 and is covered with a surface casting skin with a thickness of about 0.3 mm, is in the form of an A ⁇ column of a passenger car s configured.
  • This foam element is immersed in a polyurethane bath.
  • the properties of the liquid polyurethane, in particular the viscosity and the adhesion, are adjusted so that the thickness of an adhesive polyurethane layer is approximately 0.2 mm.
  • the hollow profile 6 of the structural element is formed from a sheet steel part.
  • the sheet metal part has already been deformed in such a way that it forms a cavity which has an opening along its longitudinal side through which the foam element is inserted into the cavity.
  • the foam element is fixed to the surface by a clamp, screw, rivet or other fastener.
  • the sheet metal part is then joined at seam 8 to form a closed surface.
  • the shape of the hollow profile is designed such that there is a slight, approximately 3 mm wide, uniform gap between the hollow profile and the coated metal foam.
  • the polyurethane coating of the foam element expands by means of a heat treatment between 170 ° C. and 180 ° C. for about 15 minutes, as a result of which the gap between the hollow profile and the foam element is closed.
  • the separating layer according to the invention is formed.
  • the heat treatment is preferably carried out simultaneously with a drying process which, after the cathode the dip painting is necessary. The provisional fixings are finally removed.
  • a foam element analogous to Example 1 is coated with polyurethane in the form of a pasty mass via a nozzle which is guided by a robot arm.
  • the coated foam element is inserted and fixed in a channel-shaped partial profile made of an aluminum alloy.
  • the foam element protrudes over the edge of the profile.
  • Another partial profile is put on, the two profiles are glued to the seams with a temperature-resistant adhesive to form a hollow profile.

Abstract

The invention relates to a structural element (6) which has a continuous surface, encompassing a hollow chamber (12), which is filled at least partially with a metal foam (21). The invention is characterised in that the metal foam and the surface are separated by a material (7) which is capable of expanding.

Description

Mit Metallschaum verstärktes Strukturelement Structural element reinforced with metal foam
Die Erfindung betrifft ein Strukturelement nach Patentanspruch 1 und ein Verfahren zur Herstellung eines Strukturelementes nach Patentanspruch β.The invention relates to a structural element according to claim 1 and a method for producing a structural element according to claim β.
Leichtbaustrukturen sind in der Verkehrstechnik, insbesondere in der Automobiltechnik eine wichtige Grundlage zur Reduzierung des Treibstoffverbrauches. Leichtbaustrukturen können ü- ber die Wahl der Werkstoffe (z. B. Aluminium) oder durch konstruktive Maßnahmen (Verwendungen von geringeren Wandstärken von Stahlkonstruktionen in Verbindungen mit Verstrebungen) oder durch Kombinationen dieser Maßnahmen realisiert werden.Lightweight structures are an important basis for reducing fuel consumption in traffic engineering, especially in automotive engineering. Lightweight structures can be realized through the choice of materials (e.g. aluminum) or through constructive measures (use of smaller wall thicknesses of steel structures in connection with struts) or through combinations of these measures.
Bei immer geringere werdenden Wandstärken der Bleche steigt die Gefahr des Einbeulens (geringere Beulfestigkeit) und des katastrophalen Einknicken des Strukturbauteils im Crashfall. Aus diesem Grund wurden in den letzen Jahren versucht, Metallschäume, die ein hohes Energieaufnahmevermögen aufweisen, in Aluminiumstrukturbauteilen oder auch in dünnwandigen Stahlstrukturbauteilen zu integrieren.With ever decreasing wall thicknesses of the sheets, the risk of denting (less dent resistance) and catastrophic buckling of the structural component in the event of a crash increases. For this reason, attempts have been made in recent years to integrate metal foams which have a high energy absorption capacity into aluminum structural components or also into thin-walled steel structural components.
Die DE 198 13 092 AI beschreibt ein Strukturelement aus Stahlblech, das mit einem Aluminiumschaum verstärkt ist. Zur Herstellung dieses Strukturelementes wird in ein Hohlprofil über eine Öffnung Aluminiumpulver, das mit einem Treibmittel versehen ist, gefüllt. Anschließend wird das Aluminiumpulver durch eine Temperaturbehandlung, die im Bereich des Schmelzpunktes von Aluminium liegt, aufgeschäumt. Der Nachteil dieser Erfindung besteht darin, dass die Temperatur zum Aufschäumen so hoch gewählt werden muß, dass die Maßhaltigkeit des Strukturelementes erheblich beeinträchtigt wird, Aluminium als formgebendes Material des Strukturelementes kommt bei dieser Erfindung nicht in Frage. Des Weiteren wird durch die unterschiedlichen elektrochemischen Spannungen an den Grenzflächen zwischen dem Aluminiumschaum und der Stahloberfläche eine Kontaktkorrosion erzeugt, die die Lebensdauer des Strukturbauteils deutlich herabsetzt.DE 198 13 092 AI describes a structural element made of sheet steel, which is reinforced with an aluminum foam. To produce this structural element, aluminum powder, which is provided with a blowing agent, is filled into a hollow profile through an opening. The aluminum powder is then foamed by a temperature treatment which is in the range of the melting point of aluminum. The disadvantage of this invention is that the temperature for foaming must be chosen so high that the dimensional stability of the structural element is considerably impaired; aluminum as the shaping material of the structural element is out of the question in this invention. Furthermore, due to the different electrochemical voltages at the interfaces between the aluminum foam and the steel surface, contact corrosion is generated, which significantly reduces the service life of the structural component.
Aus der DE 92 10 257 ül ist es bekannt, einen Aluminiumschaum in ein Hohlprofil einzukleben oder das Hohlprofil auf den Metallschaum aufzuschrumpfen. Die erste Möglichkeit hat den Nachteil, dass Toleranzen und Spielräume, die bei der Fertigung des Hohlprofils und des Aluminiumschaumbauteils auftreten nicht befriedigend ausgeglichen werden können. Eine vollständige Kraftübertragung zwischen Metallschaum und Hohlprofil ist somit nicht möglich. Das Aufschrumpfen erfordert wiederum Wärmebehandlungen, die sowohl das Gefüge des Hohlprofils als auch des Metallschaums nachhaltig schädigen und die mechanischen Eigenschaften des Bauteils negativ beeinflussen.From DE 92 10 257 ül it is known to glue an aluminum foam into a hollow profile or to shrink the hollow profile onto the metal foam. The first possibility has the disadvantage that tolerances and margins that occur during the manufacture of the hollow profile and the aluminum foam component cannot be satisfactorily compensated for. A complete power transmission between the metal foam and the hollow profile is therefore not possible. The shrinking on in turn requires heat treatments that permanently damage both the structure of the hollow profile and the metal foam and negatively affect the mechanical properties of the component.
Die Aufgabe der Erfindung besteht demnach darin, ein schaumverstärktes Strukturelement bereitzustellen, das gegenüber dem Stand der Technik eine deutlich verringerte Korrosionsneigung, eine höhere Steifigkeit und eine höher Beulfestigkeit aufweist.The object of the invention is therefore to provide a foam-reinforced structural element which, compared to the prior art, has a significantly reduced tendency to corrode, a higher rigidity and a higher dent resistance.
Die Lösung der Aufgabe besteht in einem Strukturelement nach Patentanspruch 1 und in einem Verfahren nach Patentanspruch 6.The object is achieved in a structural element according to claim 1 and in a method according to claim 6.
Das erfindungsgemäße Strukturelement nach Patentanspruch 1 weist ein Hohlprofil auf, das die äußere Form des Strukturelementes darstellt und einen Hohlraum bildet. Ein derartiges Strukturelement ist an sich als Bauelement einsetzbar und selbsttragend. Zur Verbesserung der mechanischen Eigenschaften, insbesondere der Beulfestigkeit, ist das Strukturelement mit einem Metallschaum (Schaumelement) , der den Hohlraum zumindest teilweise ausfüllt, verstärkt.The structural element according to the invention has a hollow profile, which represents the outer shape of the structural element and forms a cavity. Such a structural element can be used as a component and self-supporting. To improve the mechanical properties, in particular the buckling resistance, the structural element is reinforced with a metal foam (foam element) which at least partially fills the cavity.
Das erfindungsgemäße Strukturelement weist zudem eine Trennschicht zwischen dem Schaumelement und einer inneren Oberfläche des Hohlprofils auf, die aus einem expandierten Material besteht. Das expandierte Material geht auf ein expansionsfähiges Material zurück, das bei einer Temperaturbehandlung und/oder einer chemischen Behandlung sein Volumen vergrößert. Dies kann ein Expansionsklebstoff oder ein Quellschaum oder ein niedrig schmelzender Metallschaum sein. Besonders geeignet sind Schäume auf der Basis von Polyurethanen oder Epoxid.The structural element according to the invention also has a separating layer between the foam element and an inner surface of the hollow profile, which is made of an expanded material. The expanded material is based on an expandable material that increases its volume during a temperature treatment and / or a chemical treatment. This can be an expansion adhesive or a swelling foam or a low melting metal foam. Foams based on polyurethane or epoxy are particularly suitable.
Diese Trennschicht verhindert eine Kontaktkorrosion, die in der Regel dann auftritt, wenn Metalle mit unterschiedlichen elektrochemischen Potentialen miteinander in Berührung kommen.This separating layer prevents contact corrosion, which usually occurs when metals with different electrochemical potentials come into contact with one another.
Ein weiterer Vorteil der Trennschicht ist, dass durch diese Schicht Toleranzen, die bei der Fertigung des Hohlprofils bzw. des Schaumelementes, die zum Einbringen des Schaumelements in den Hohlraum notwendig sind, kompensiert werden können. Dieser Vorteil des erfindungsgemäßen1 Strukturelementes kommt auch dann zum tragen, wenn das Hohlprofil durch einen nichtmetallischen Werkstoff, wie z. B. Polyethylen oder einen Verbundwerkstoff wie z. B. kohlefaserverstärkte Kunststoffe (CFK) dargestellt wird.Another advantage of the separating layer is that tolerances which can be compensated for in the manufacture of the hollow profile or the foam element, which are necessary for introducing the foam element into the cavity, can be compensated for by this layer. This advantage of the 1 structural element according to the invention also comes into play when the hollow profile is made of a non-metallic material, such as. B. polyethylene or a composite material such. B. carbon fiber reinforced plastics (CFRP) is shown.
Ferner übernimmt die erfindungsgemäße Trennschicht kraftübertragende Funktionen zwischen dem Schaumelement und dem Hohlprofil des Strukturelements und trägt somit zur Steigerung der Karosseriesteifigkeit bei.Furthermore, the separating layer according to the invention takes over force-transmitting functions between the foam element and the hollow profile of the structural element and thus contributes to increasing the body rigidity.
Die Dicke der Trennschicht beträgt in der Regel zwischen 0,5 mm und 15 mm, besonders bevorzugt zwischen 1 mm und 3 mm. In den meisten Fällen wird das Hohlprofil des erfindungsgemäßen Strukturelementes durch Bleche geformt. Dies bietet Vorteile beim Einbringen des Schaumelements in den Hohlraum, insbesondere wenn das Hohlprofil aus zwei oder mehreren Einzelteilen (Teilprofil) gefertigt wird. Ebenso ist es möglich, das Hohlprofil durch Strangpreßprofile oder Gußteile darzustellen. In diesen Fällen sollte der Hohlraum mindestens an einer Seite offen zugänglich sein, damit das Schaumelement in den Hohlraum des Hohlprofils eingeführt werden kann (Anspruch 2) .The thickness of the separating layer is generally between 0.5 mm and 15 mm, particularly preferably between 1 mm and 3 mm. In most cases, the hollow profile of the structural element according to the invention is formed by metal sheets. This offers advantages when introducing the foam element into the cavity, in particular if the hollow profile is made from two or more individual parts (partial profile). It is also possible to represent the hollow profile by means of extruded profiles or cast parts. In these cases, the cavity should be openly accessible on at least one side so that the foam element can be inserted into the cavity of the hollow profile (claim 2).
Die gebräuchlichsten Strukturwerkstoffe sind insbesondere in der Automobiltechnik Legierungen auf Eisenbasis oder Aluminiumbasis oder Magnesiumbasis. Die Vorteile dieser Werkstoffe liegen in ihrer guten Verarbeitbarkeit und in den relativ geringen Herstellungskosten. Die bereits erwähnte Korrosionsbildung zwischen dem Schaumelement und dem metallischen Hohlprofil ist durch den Einsatz der erfindungsgemäßen Trennschicht aus expansionsfähigem Material weitgehend unterbunden. Die Verwendung von Hohlprofilen aus Kunststoffen kann dennoch in einzelnen Fällen zweckmäßig sein, wenn erhöhte Fertigungskosten bei einer weiteren Gewichtsreduktion des Strukturelementes akzeptiert werden können (Anspruch 3).The most common structural materials, particularly in automotive engineering, are iron-based or aluminum-based or magnesium-based alloys. The advantages of these materials are their good processability and the relatively low manufacturing costs. The already mentioned formation of corrosion between the foam element and the metallic hollow profile is largely prevented by the use of the separating layer according to the invention made of expandable material. The use of hollow profiles made of plastics can nevertheless be expedient in individual cases if increased manufacturing costs can be accepted with a further weight reduction of the structural element (claim 3).
Die Kräfte, die auf das Strukturelement wirken, sind auf bevorzugte Raumrichtungen ausgerichtet. Es ist demnach im Sinne der Erfindung zweckmäßig, den Hohlraum insbesondere entlang dieser Kraftrichtungen mit Metallschaum auszufüllen, so dass diese Kräfte kompensiert werden können. Hierdurch erfolgt bei annähernd gleicher Stabilität des Strukturelementes eine weitere Gewichtsreduktion, ferner werden Materialkosten eingespart, da weniger Metallschaum eingesetzt wird (Anspruch 4) .The forces that act on the structural element are aimed at preferred spatial directions. It is therefore expedient in the sense of the invention to fill the cavity with metal foam, in particular along these directions of force, so that these forces can be compensated for. This results in a further weight reduction with approximately the same stability of the structural element, and material costs are also saved since less metal foam is used (claim 4).
Metallschäume auf der Basis von Aluminium und/oder Zink weisen ein hohes Maß an Energieaufnahmevermögen auf und sind auf Grund der relativ geringen Schmelztemperatur von dieser Me- talle mit vergleichsweise geringem technischen Aufwand herstellbar (Anspruch 5) .Metal foams based on aluminum and / or zinc have a high degree of energy absorption and are due to the relatively low melting temperature of this talle producible with comparatively little technical effort (claim 5).
Ein weiterer Gegenstand der Erfindung nach Patentanspruch 6 ist ein Verfahren zur Herstellung eines Strukturelementes, das durch ein Hohlprofil gebildet wird und durch ein Schaumelement verstärkt wird. Die für die Patentansprüche eins bis fünf genannten Vorteile gelten ebenfalls für das Verfahren nach Patentanspruch 6.Another object of the invention according to claim 6 is a method for producing a structural element which is formed by a hollow profile and is reinforced by a foam element. The advantages mentioned for claims one to five also apply to the method according to claim 6.
Das erfindungsgemäße Verfahren zeichnet sich dadurch aus, dass ein Schaumelement und/oder ein Hohlprofil, die in ihrer Form an einander angepaßt sind, mit einem expansionsfähigen Material versehen werden. Hierbei ist es möglich das z. B. Schaumelement in ein Bad mit flüssigem expansionsfähigen Material zu tauchen oder es mit dem expansionsfähigen Material zu bestreichen oder zu besprühen. Hierbei ist es notwendig, die Viskosität des expansionsfähigen Materials auf die Anforderung der genannten Aufbringungstechniken anzupassen.The method according to the invention is characterized in that a foam element and / or a hollow profile, the shape of which is matched to one another, is provided with an expandable material. It is possible that the z. B. immerse foam element in a bath with liquid expandable material or to coat or spray it with the expandable material. It is necessary to adjust the viscosity of the expandable material to the requirements of the application techniques mentioned.
In einem weiteren Verfahrensschritt wird das mit expansionsfähigen Material beschichtete Schaumelement in den Hohlraum eingeführt. Es ist hierbei notwendig, dass das Hohlprofil bei diesem Verfahrensschritt eine hinreichend große Öffnung aufweist, durch die das Schaumelement eingebracht werden kann und die im weiteren Verfahrensablauf verschlossen wird. Nach diesem Verfahrensschritt befindet sich ein definierter Spielraum zwischen dem Schaumelement und dem Hohlprofil. Zur Vermeidung eines gegenseitigen Verschiebens zwischen dem Hohlprofil und dem Schaumelement ist es zweckmäßig, das Schaumelement am Hohlprofil mechanisch, z. B. durch Klammern oder Schrauben zu fixieren.In a further process step, the foam element coated with expandable material is introduced into the cavity. It is necessary here that the hollow profile in this process step has a sufficiently large opening through which the foam element can be introduced and which is closed in the further course of the process. After this process step there is a defined scope between the foam element and the hollow profile. To avoid mutual displacement between the hollow profile and the foam element, it is expedient to mechanically, for. B. to fix by clamps or screws.
Besonders geeignet ist hierfür ein mehrteiliges Hohlprofil, bei der die einzelnen Teile durch Verkleben, Verschweißen, Nieten, Falzen oder durch lösbare Verbindungen zusammengefügt werden. Das Einbringen des Schaumelements in ein mehrteiliges Hohlprofil vereinfacht den Verfahrensprozeß erheblich.A multi-part hollow profile is particularly suitable for this, in which the individual parts are joined together by gluing, welding, riveting, folding or by detachable connections become. The introduction of the foam element into a multi-part hollow profile considerably simplifies the process.
Im Anschluß erfolgt eine Wärmebehandlung, z. B. nach dem Ka- thoden-Tauchlackieren die im Rahmen der Prozeßführung zur Herstellung von Karosserieteilen ohnehin notwendig ist. Während dieser Wärmebehandlung expandiert das expansionsfähige Material und es wird eine kraftschlüssige Verbindung mit dem Hohlprofil gebildet, die gleichzeitig als Korrosionsschutz zwischen dem Hohlprofil und dem Schaumelement dient. Durch die Einbindung in eine verfahrensnotwendige Wärmebehandlung können zusätzlich Verfahrenskosten eingespart werden.This is followed by a heat treatment, e.g. B. after the cathode dip painting which is necessary anyway in the course of the process for the production of body parts. During this heat treatment, the expandable material expands and a non-positive connection is formed with the hollow profile, which also serves as a protection against corrosion between the hollow profile and the foam element. By integrating it into a heat treatment that is necessary for the process, additional process costs can be saved.
Vorteilhafte Ausgestaltungen der Erfindung werden an Hand der folgenden Ausführungsbeispiele näher erläutert.Advantageous embodiments of the invention are explained in more detail with reference to the following exemplary embodiments.
Es zeigen:Show it:
Fig. 1 ein Schaumelement in Form eines Quaders.Fig. 1 is a foam element in the form of a cuboid.
Fig. 2 ein Schaumelement mit einem x-förmigen Querschnitt.Fig. 2 is a foam element with an x-shaped cross section.
Fig. 3 ein Schaumelement aus Fig. 1, teilweise mit einem expansionsfähigen Material versehen.Fig. 3 shows a foam element from Fig. 1, partially provided with an expandable material.
Fig. 4 ein Strukturelement mit einem Hohlprofil und einem quaderförmigen Schaumelement nach Fig. 1.4 shows a structural element with a hollow profile and a cuboid foam element according to FIG. 1.
Fig. 5 ein Strukturelement mit einem Hohlprofil und einem Schaumelement nach Fig. 2.5 shows a structural element with a hollow profile and a foam element according to FIG. 2.
Die Figuren 1 und 2 zeigen jeweils ein Beispiel für ein Schaumelement 2 und 2λ. Das Schaumelement 2 aus Figur 1 ist als Vollkörper ausgebildet und der Form des Strukturelementes angepaßt. Die quaderförmige Darstellung ist exemplarisch, e- benso könnte das Schaumelement in gebogener und/oder abgerundeter Form dem Strukturelement angepaßt sein. Die Figur 2 zeigt ein Schaumelement 2X, das das Strukturelement teilweise, insbesondere in Richtung der wesentlichen Belastungen ausfüllt. Exemplarisch ist das Schaumelement mit einem x-förmigen Querschnitt ausgebildet. Die Winkel des x sind den Anforderungen des Strukturbauteils anzupassen. Ebenso sind andere, z. B. T-förmige, O-förmig, L-förmige oder komplexere Querschnitte denkbar.Figures 1 and 2 each show an example of a foam element 2 and 2 λ . The foam element 2 from FIG. 1 is designed as a solid body and is adapted to the shape of the structural element. The cuboid representation is exemplary; the foam element could also be adapted to the structural element in a curved and / or rounded shape. FIG. 2 shows a foam element 2 X which partially fills the structural element, in particular in the direction of the essential loads. As an example, the foam element is designed with an x-shaped cross section. The angles of the x are to be adapted to the requirements of the structural component. Likewise, others, e.g. B. T-shaped, O-shaped, L-shaped or more complex cross sections conceivable.
Die Figur 3 zeigt das Schaumelement 2 das, in diesem Fall teilweise mit einem expansionsfähigen Material 4 versehen ist. Das expansionsfähige Material 4 ist so aufgebracht, dass eine Berührung zwischen einem Hohlprofil 6 des Strukturelements 1 und einem Schaumelement 2 vermieden wird.FIG. 3 shows the foam element 2, which in this case is partially provided with an expandable material 4. The expandable material 4 is applied in such a way that contact between a hollow profile 6 of the structural element 1 and a foam element 2 is avoided.
Die Figuren 4 und 5 zeigen Beispiele für ein Strukturelement, zum einen mit einer Vollschaumfüllung (Figur 4) bzw. mit einer teilweisen Schaumfüllung mit einem x-förmigen Querschnitt (Figur 5) . Beide Strukturelemente weisen eine erfindungsgemäße Trennschicht 7 zwischen dem Hohlprofil 6 und dem Schaumelement 5 auf. Das Hohlprofil 6 des Strukturelementes aus den Figuren 5 und 6 ist einteilig ausgebildet und an einer Naht 8 punktgeschweißt. Ebenso ist es möglich, die Oberfläche β des Strukturelementes 1 mehrteilig, insbesondere in Form von zwei Halbschalen zu gestalten.FIGS. 4 and 5 show examples of a structural element, on the one hand with a full foam filling (FIG. 4) or with a partial foam filling with an x-shaped cross section (FIG. 5). Both structural elements have a separating layer 7 according to the invention between the hollow profile 6 and the foam element 5. The hollow profile 6 of the structural element from FIGS. 5 and 6 is formed in one piece and spot welded to a seam 8. It is also possible to design the surface β of the structural element 1 in several parts, in particular in the form of two half-shells.
Das Strukturbauteil ist bevorzugt als Karosserieteil in einem Automobil ausgestaltet. Es kann hierbei tragende Funktionen in der Bodengruppe (z. B. als Schweller, Längs- oder Querträger des Motors) übernehmen oder als A-, B- oder C-Säule im Karosserieaufbau eingesetzt sein. Die Form des Strukturelementes ist demnach den konstruktionsbedingten Anforderungen angepaßt. Zudem können erfindungsgemäße Strukturelemente im Fahrwerksbereich und in Motoren eingesetzt werden.The structural component is preferably designed as a body part in an automobile. It can perform load-bearing functions in the floor assembly (e.g. as a sill, longitudinal or cross member of the engine) or can be used as an A, B or C pillar in the body structure. The shape of the structural element is therefore adapted to the design-related requirements. In addition, structural elements according to the invention can be used in the chassis area and in engines.
Die Naht 8 ist in den Figuren 4 und 5 lediglich schematisch dargestellt. Generell können alle in der Herstellung von Strukturbauteilen üblichen Fügeverfahren angewandt werden, das gilt insbesondere für das Falzen, Schweißen, Kleben, Löten, Schrauben oder Nieten.The seam 8 is shown only schematically in FIGS. 4 and 5. Generally speaking, everyone in the manufacture of Structural components usual joining methods are used, this applies in particular to the folding, welding, gluing, soldering, screwing or riveting.
Die folgenden Beispiele beschreiben ein Verfahren zur Herstellung eines erfindungsgemäßen Strukturelementes.The following examples describe a method for producing a structural element according to the invention.
Beispiel 1example 1
Ein Schaumelement auf Aluminiumbasis (Legierung A1SÜ2) , das eine Porosität von 70% und somit eine Dichte von 0,81 g/cm3 aufweist und mit einer oberflächlichen Gußhaut mit einer Dicke von etwa 0,3 mm bedeckt ist, ist in Form einer A-Säule eines PkwΛs ausgestaltet. Dieses Schaumelement wird in ein Polyurethan-Bad getaucht. Die Eigenschaften des flüssigen Polyurethans, insbesondere die Viskosität und die Haftung sind so eingestellt, dass die Dicke einer haftenden Polyurethanschicht etwa 0,2 mm beträgt.An aluminum-based foam element (alloy A1SÜ2), which has a porosity of 70% and thus a density of 0.81 g / cm 3 and is covered with a surface casting skin with a thickness of about 0.3 mm, is in the form of an A Λ column of a passenger car s configured. This foam element is immersed in a polyurethane bath. The properties of the liquid polyurethane, in particular the viscosity and the adhesion, are adjusted so that the thickness of an adhesive polyurethane layer is approximately 0.2 mm.
Das Hohlprofil 6 des Strukturelementes wird aus einem Stahlblechteil geformt. Das Blechteil ist bereits so umgeformt, dass es einen Hohlraum bildet, der entlang seiner Längsseite eine Öffnung aufweist, durch die das Schaumelement in den Hohlraum eingelegt wird. Das Schaumelement wird durch eine Klammer, Schraube, Niete oder ein anderes Befestigungsmittel an der Oberfläche fixiert. Anschließend erfolgt das Fügen des Blechteils an der Naht 8 zu einer geschlossenen Oberfläche. Die Form des Hohlprofils ist so ausgebildet, dass sich zwischen dem Hohlprofil und dem beschichteten Metallschaum ein geringfügiger etwa 3 mm breiter gleichmäßiger Spalt befindet.The hollow profile 6 of the structural element is formed from a sheet steel part. The sheet metal part has already been deformed in such a way that it forms a cavity which has an opening along its longitudinal side through which the foam element is inserted into the cavity. The foam element is fixed to the surface by a clamp, screw, rivet or other fastener. The sheet metal part is then joined at seam 8 to form a closed surface. The shape of the hollow profile is designed such that there is a slight, approximately 3 mm wide, uniform gap between the hollow profile and the coated metal foam.
Durch eine Wärmebehandlung zwischen 170° C und 180° C für etwa 15 min, expandiert die Polyurethanbeschichtung des Schaumelements, hierdurch wird der Spalt zwischen Hohlprofil und Schaumelement geschlossen die erfindungsgemäße Trennschicht wird ausbildet. Die Wärmebehandlung erfolgt vorzugsweise gleichzeitig mit einem Trocknungsprozeß, der nach der Katho- den-Tauchlackierung notwendig ist. Die vorläufigen Fixierungen werden abschließend entfernt.The polyurethane coating of the foam element expands by means of a heat treatment between 170 ° C. and 180 ° C. for about 15 minutes, as a result of which the gap between the hollow profile and the foam element is closed. The separating layer according to the invention is formed. The heat treatment is preferably carried out simultaneously with a drying process which, after the cathode the dip painting is necessary. The provisional fixings are finally removed.
Beispiel 2Example 2
Ein Schaumelement analog zu Beispiel 1 wird über eine Düse, die von einem Roboterarm geführt wird mit Polyurethan in Form einer pastösen Masse beschichtet. Das beschichtete Schaumelement wird in ein rinnenförmiges Teilprofil aus einer Aluminiumlegierung eingelegt und fixiert. Das Schaumelement steht über den Rand des Profils über. Ein weiteres Teilprofil wird aufgesetzt, die beiden Profile werden an den Nahtstellen mit einem temperaturbeständigen Klebstoff zu einem Hohlprofil verklebt.A foam element analogous to Example 1 is coated with polyurethane in the form of a pasty mass via a nozzle which is guided by a robot arm. The coated foam element is inserted and fixed in a channel-shaped partial profile made of an aluminum alloy. The foam element protrudes over the edge of the profile. Another partial profile is put on, the two profiles are glued to the seams with a temperature-resistant adhesive to form a hollow profile.
Analog dem Beispiel 1 besteht auch ein Spalt zwischen dem Hohlprofil und dem Schaumelement, der während einer Wärmebehandlung durch das expedierende Polyurethan ausgefüllt wird. Die Wärmebehandlung erfolgt indem das Strukturbauteil durch eine Induktionsspule geführt wird. Das hierdurch erwärmte A- luminium überträgt seine Wärme auf das Polyurethan, wodurch die Expansion ausgelöst wird. Analogously to example 1, there is also a gap between the hollow profile and the foam element, which is filled by the expending polyurethane during a heat treatment. The heat treatment is carried out by passing the structural component through an induction coil. The aluminum thus heated transfers its heat to the polyurethane, which triggers the expansion.

Claims

Patentansprücheclaims
1. Strukturelement, das ein Hohlprofil mit einen Hohlraum umfaßt, der zumindest teilweise mit einem Metallschaum ausgefüllt ist, da durch gekennzeichnet, dass das Strukturelement zwischen dem Metallschaum und der 0- berfläche des Hohlprofils eine Trennschicht aus expandiertem Material aufweist.1. Structural element comprising a hollow profile with a cavity which is at least partially filled with a metal foam, characterized in that the structural element has a separating layer made of expanded material between the metal foam and the surface of the hollow profile.
2. Strukturelement nach Anspruch 1 da durch gekennzeichnet, dass das Hohlprofil in Form von Blechen, Strangpreßprofilen o- der Gußteilen ausgebildet ist.2. Structural element according to claim 1, characterized in that the hollow profile is in the form of sheets, extruded profiles or castings.
3. Strukturelement nach Anspruch 1 oder 2, da durch gekennzeichnet, dass das Hohlprofil aus Aluminium oder aus Eisen oder aus Magnesium, aus Legierungen dieser Metalle oder aus Kunsstoff besteht .3. Structural element according to claim 1 or 2, characterized in that the hollow profile consists of aluminum or iron or magnesium, alloys of these metals or plastic.
4. Strukturelement nach einem der vorhergehenden Ansprüche, da durch gekennzeichnet, dass der Hohlraum in die Raumrichtung mit dem Metallschaum verstärkt ist, in denen erhöhte Spannungen auf das Strukturelement wirken.4. Structural element according to one of the preceding claims, characterized in that the cavity is reinforced in the spatial direction with the metal foam, in which increased stresses act on the structural element.
5. Strukturelement nach einem der vorhergehenden Ansprüche, da durch gekennzeichnet, dass der Metallschaum im Wesentlichen aus Aluminium oder Zink oder aus einer Legierung dieser Metalle besteht. β. Verfahren zur Herstellung eines Strukturelementes, das von einem Hohlprofil umschlossen wird und durch einen Metallschaum mindestens teilweise ausgefüllt wird, da durch gekennzeichnet, dass der Metallschaum und/oder das Hohlprofil zumindest teilweise mit einem expansionsfähigen Material beschichtet wird, der Metallschaum mit dem expansionsfähigen Material in einen Hohlraum des Hohlprofils gegeben wird, durch eine Temperaturbehandlung das expansionsfähige Material expandiert und Zwischenräume zwischen dem Metallschaum und des Hohlprofils durch das expansionsfähige Material ausgefüllt werden.5. Structural element according to one of the preceding claims, characterized in that the metal foam consists essentially of aluminum or zinc or an alloy of these metals. β. Method for producing a structural element which is enclosed by a hollow profile and is at least partially filled by a metal foam, since characterized in that the metal foam and / or the hollow profile is at least partially coated with an expandable material, the metal foam with the expandable material in one Given cavity of the hollow profile, the expandable material is expanded by a thermal treatment and gaps between the metal foam and the hollow profile are filled by the expandable material.
7. Verfahren nach Anspruch 6, dadurch gekennzeichnet, dass der beschichtete Metallschaum vor der Wärmebehandlung im Hohlraum fixiert wird.7. The method according to claim 6, characterized in that the coated metal foam is fixed in the cavity before the heat treatment.
8. Verfahren nach Anspruch 6, da durch gekennzeichnet, dass die Temperaturbehandlung im Rahmen eines Vergütungsverfahrens des Strukturelements erfolgt. 8. The method according to claim 6, characterized in that the temperature treatment is carried out as part of a compensation process of the structural element.
PCT/EP2001/014438 2001-01-16 2001-12-08 Structural element reinforced with metal foam WO2002055923A2 (en)

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WO2006015248A3 (en) * 2004-07-30 2006-04-27 L & L Products Inc Member for reinforcing, sealing or baffling and system formed therewith
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US8475694B2 (en) 2005-10-25 2013-07-02 Zephyros, Inc. Shaped expandable material
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WO2008110347A1 (en) * 2007-03-12 2008-09-18 Zephyros Inc Improved reinforcing structure
US7735906B2 (en) 2007-09-28 2010-06-15 Zephyros, Inc. Reinforcement system for an automotive vehicle
US10457840B2 (en) 2010-09-30 2019-10-29 Zephyros, Inc. Foamed adhesive
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EP3932751A1 (en) * 2020-07-02 2022-01-05 Havel metal foam GmbH Underride protection for a vehicle with metal foam in a hollow profile

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