WO2010100165A1

WO2010100165A1 - Weight-optimized vehicle door

Info

Publication number: WO2010100165A1
Application number: PCT/EP2010/052642
Authority: WO
Inventors: Wolfgang Dietz; Markus Golda
Original assignee: Magna Steyr Fahrzeugtechnik Ag & Co Kg; Volk, Robert
Priority date: 2009-03-02
Filing date: 2010-03-02
Publication date: 2010-09-10

Abstract

The invention relates to a vehicle door comprising a one-piece load-bearing door structure made of a structural component composed of fiber-reinforced plastic and/or metal that at least partially forms the contour of the side of the vehicle door facing the passenger compartment.

Description

Weight-optimized vehicle door

The invention relates to a vehicle door.

Doors in shell construction are known from the prior art. These have individual self-supporting shells on which obtained by various joining processes, such as welding, clinching, riveting, screws, clamps and / or gluing, their shape and stability in terms of strength and rigidity.

It is an object of the present invention to realize a particularly inexpensive vehicle door.

This object is achieved by a vehicle door according to claim 1.

Characterized in that the vehicle door has a one-piece supporting door structure of a structural component made of fiber-reinforced plastic and / or metal at least partially forms the contour or shape of the passenger compartment side facing the vehicle door, a separate interior trim can be omitted at least partially.

According to a particular embodiment of the invention, a window receiving space is provided in the structural component.

According to a particular embodiment of the invention, the structural component has a sandwich structure, wherein one or more stiffening structures, for example foams and / or webs, are arranged between two carrier layers.

According to a particular embodiment of the invention, a cover, for example made of metal or plastic, is provided on the outside of the vehicle door on the structural component, which cover is suitable for forming a part of the outer skin of a vehicle.

According to a particular embodiment of the invention, the structural component forms a cavity.

According to a particular embodiment of the invention, the window receiving space is arranged as part of the cavity and does not have the limiting structural component in this area Openings to, the passenger compartment facing side of the vehicle door.

According to a particular embodiment of the invention, the cavity to the outside of the vehicle door is open, so that easy assembly and service work on an attachment are feasible.

According to a particular embodiment of the invention, all the required attachments such as hinges, door brake, lock, window frames, seals, speakers, wiring harness, door trim on the structural component, in particular screwed, clipped, glued and / or inserts, fastened.

According to a particular embodiment of the invention, an inner component such as a door handle and / or an armrest and / or a map pocket can be fastened to the structural component directly or via a door trim on the inside of the structural component.

According to a particular embodiment of the invention, flat conductors and / or flexible printed boards are provided for the electrical supply of the attachments located in the door, which are fastened in a suitable manner to the structural component. Flexible printes boards are insulating films with, for example vapor-deposited, conductive layer called.

According to a particular embodiment of the invention, the structural component for noise reduction, in particular for better absorption of disturbing noises, preferably on the inside of the cavity, one or more openings.

According to a particular embodiment of the invention, the vehicle door is designed in particular with regard to structural strength and functional performance. According to a particular embodiment, the door structure already has a fully or partially integrated door trim. The surfaces of this door panel integrated in the structure may be versatile, e.g. Paint, foil, leather, fabric, structure by grained tool, etc.

Various embodiments of the invention are as follows several schematic non-limiting figures explained in more detail:

Fig. 1 shows an external perspective view of the structural component

Fig. 2 shows an inside perspective view of the structural component

3 shows a further perspective external view of the structural component

4 and 5 show further perspective exterior views of the structural component with attachments

Fig. 6 shows a cross section through the structural component

Fig. 7 and 8 show the schematic structure of second different special embodiments of a structural component

9 shows a cross section through a structural component with various detail views

FIG. 1 shows a structural component 1 in a perspective external view. Such a view would correspond to the view of a position outside the vehicle. The drilled structural component was made of a fiber-reinforced plastic and forms the supporting element of a side door of a vehicle. In the view of FIG. 1, the outside view of the side door can be seen, wherein the outwardly open cavity 2 of the structural component 1 is very well visible. A flange 10 is provided on which a cover (not shown) is attached, which forms part of the outer skin of the vehicle door or of the vehicle. The structural component 1 also forms a window receiving space 24, which is provided in particular as part of the cavity 2, so that the window can be sunk, for example, in the cavity 2 of the structural part 1 and the structural component 1 seals the cavity against the passenger compartment, so that no along the disc running rainwater can penetrate into this.

FIG. 2 shows the structural component 1 in a perspective interior view. Such a view would be consistent with the view from the passenger compartment of a vehicle. In this illustration, the inner contour 3 of the structural component 1 can be seen, which forms part of the inner contour of the vehicle door. As interior components 4, an armrest 5 and a door handle 6 are fastened to the structural component 1. As can be seen from the synopsis of FIG. 1 and FIG. 2, the cavity 1 forms the inner contour 3 on its opposite side on the inside of the door.

In Fig. 3, in addition to the known elements, an impact beam 7 is shown as a reinforcing element that is fixed in a diagonal arrangement on the structural component 1 and this reinforced.

In Fig. 4 is an extension to Fig. 3, an attachment 8, for example, an electric window, shown. Further, in Fig. 3 and in Fig. 4 of the window frame 9 for receiving the side window can be seen.

Fig. 5 shows a dashed line the course of flat cables and plugs 11 for the electrical supply of attachments, such as the power window.

6 shows a cross section through the structural component 1, wherein the sandwich structure of the same, which essentially comprises a first carrier layer 12 and a second carrier layer 13 and a stiffening structure 14 arranged therebetween, for example a plastic foam, a honeycomb material or a cell structure with webs , as shown in Fig. 6, consists. The first carrier layer is formed in FIG. 6, for example, by laminate layers. Furthermore, the ribbon cables 17 used can be arranged between the laminate layers, for example the second carrier layer 13. Reference numeral 11 denotes a plug connection which consists of a first plug 15 connected to the sandwich structure and a mating plug 16.

In Fig. 7, the schematic structure of a possible structural component 1 is shown in sandwich construction. In this case, a stiffening structure 14, for example made of paper, is arranged between a first carrier layer 12 and a second carrier layer 13. Should that be necessary, further separating layers 18 can be provided. After a special one Embodiment, the support layers of Galsfasermatten with epoxy resin and the stiffening structure made of a paper honeycomb core.

FIG. 8 shows a cross section of the structural component 1, with the structural component 1 having openings 19 in the first carrier layer 12 in this area on the side facing away from the passenger compartment. Through these openings penetrate driving noise (shown schematically by arrows 20), which are damped in the structure. These openings 19 of the structural component are preferably located in the cavity 2.

FIG. 9 shows in a cross section the structural component 1 with a cover 21, for example made of metal. The cover is fastened, for example via a screw 22 to the structural component 1. As is further apparent from FIG. 9, an attachment 23 is provided on the structural component 1 and suitably fastened. In a detailed view is shown how the attachment 23 is attached via a glued-insert and a suitable screw on the structural component 1.

In addition, a region of variable thickness of the structural component 1 is shown in a detailed view, wherein an adapted layer thickness of the stiffening structure 14 is provided between the first carrier layer 12 and the second carrier layer 13 in accordance with the required structural strength.

According to a particular embodiment, the vehicle door according to the invention has the following differences from a conventional conventional vehicle door in shell construction:

- supporting inner part consisting of tensile cover layers with a pressure-resistant core to achieve the structure goal. Separate reinforcement parts required only when required (e.g., side impact beams, window frames with parapet reinforcement)

- supporting inner part which has the complete or partial form of the door panel

- Carrying inner part with the exception of the inside door handle and the gap for side window lowering completely closed, therefore no additional water separator required - supporting inner part in sandwich construction can take over the function of the sound and temperature insulation in whole or in part

- Geometric door design so that weight optimization can be achieved through partial reduction and material substitution

- Inclusion of all necessary attachments by gluing, screwing, clipping and all Klemmfügemethoden

- Integration of many functions and reduction of redundant functions in an extended door structure with necessary attachments

According to a particular embodiment, the present invention provides, inter alia, the following tasks:

- Simplification of complexity

- Part reduction through functional integration

- drastic saving of one-off costs (development, tool)

- weight reduction

According to a particular embodiment of the invention is a door structure in a sandwich construction of a fiber-reinforced sandwich plastic, such as glass, carbon fiber, aramid fiber or boron fiber or the like, or metal, eg. Also sheet-sandwich construction conceivable, provided, which takes over the contour of the interior trim largely and is decorated accordingly. In this case, the vehicle door essentially consists of a sandwich component (made of metal or glass-fiber reinforced plastic) with a honeycomb or foam core, as can be seen for example in FIG. 7 or 9, which on the one hand on the side facing the vehicle interior, at least partially the contour of

Interior lining of the vehicle door forms and on the other hand, on the side facing away from the passenger compartment forms a cavity which is firmly closed with a removable (eg by screwing) outer skin of metal or plastic, which forms the vehicle outer skin. In this cavity, as in known vehicle doors required for the performance of a vehicle door parts, such as side impact beams, lock or electric motors for electric windows, etc., and installed by means of in attached to the structure (and usually glued with this) inserts or inserts attached.

Functions such as door pull handle / armrests or map pocket can be taken over by a local smaller door trim, which is suitably attached to the structural component.

The core of the sandwich construction is as a honeycomb core made of different materials, eg. Aluminum, thermoplastic, paper, or the like, or else as foaming agent, e.g. Made of PU foam executable.

The door structure, in cooperation with a conventional impact beam system, performs safety and structural functions and requirements. The connection of all required attachments such as hinges, door brake, lock, window frames, seals, speakers, wiring harness, door trim, etc. takes place by means of so-called set in the door structure inserts into which the above components can be screwed, clipped or glued.

The door structure also serves as a separation between the wet and the dry space of the door, wherein in the door structure are preferably provided except for the opening for the inner handle and the lower side window no openings to the interior. This results in a significant advantage over known vehicle doors by a seal with films or water separators for the separation of dry and wet rooms is no longer necessary because essentially no required for assembly or repair in conventional doors openings in the interior, with the conventional Cladding parts must be clipped, more are required. Due to the reduction of openings in the interior space associated with this invention, a significant reduction of the special acoustic measures is also accompanied. All necessary door attachments are accessible from the outside via a removable outer skin, such as a sheet metal outer skin, as a cover plate, which is why the assembly and repair work can be simplified.

In addition, ribbon cables can be embedded in the door structure, which the electr. Supply attachments with energy. This leads by the missing wiring harness to a simplification during assembly and, since no wiring harness strikes the door structure to a lower risk of noise during poor travel. Furthermore, a better protection of the cable is given as they are embedded in the structure and there is a space gain with less weight and a related cost advantage.

By using the sandwich construction of fiber-reinforced plastic or metal, noise in the structure can be better absorbed. On the one hand, this results from the generally higher stiffness of the sandwich construction and, on the other hand, for example, by attaching openings in the interior of the vehicle door in which the sound can run dead. According to a particular embodiment of the invention, the following advantages can be achieved:

- an expected weight saving compared to a conventional steel door of up to 35%

- a simplification of the complexity of the structure and a reduction of the components

- A reduction in weight achieved through simplification and new manufacturing technology, as well as cost reduction achieved for small batches

- Use of the door shell as a drying room and use of the structure for sound-absorbing measures

- An integration of electrical wiring for windows, lock system, lights, speakers and other attachments in the structure

According to various embodiments of the invention, the door structure has a glass fiber reinforced sandwich construction with a honeycomb core. A reduction of the parts of the vehicle door is possible by integrating as many functions as possible into the component structure. According to a particular embodiment, the supporting sandwich structure has a bolted aluminum side impact beam and a window frame. According to a particular embodiment, a partial representation of the surface for the interior takes place through the structural component. According to a particular embodiment, at least one ribbon cable for power supply, for example, the door lock, arranged in the door Speaker and / or window lifter, integrated into the sandwich structure of the structural component. According to particular embodiments, the following advantages can be realized by the invention:

20-30 percent weight saving compared to conventional steel door and / or

Partial reduction through functional integration rigidity, safety, comfort, electrical and / or

Lower tool costs due to easier manufacturability

Claims

Claims:

1. Vehicle door with a one-piece supporting door structure of a structural component of fiber-reinforced plastic and / or metal which at least partially forms the contour of the passenger compartment side facing the vehicle door.

2. Vehicle door according to claim 1, characterized in that a window receiving space is provided in the structural component.

3. Vehicle door according to claim 1 or 2, characterized in that the structural component has a sandwich structure, wherein between two carrier layers one or more stiffening structures, such as foams and / or webs, are arranged.

4. Vehicle door according to one of the preceding claims, characterized in that on the outside of the vehicle door to the structural component, a cover, for example of metal or plastic, is provided, which is adapted to form a part of the outer skin of a vehicle.

5. Vehicle door according to one or more of the preceding claims, characterized in that the structural component forms a cavity.

6. Vehicle door according to claim 5, characterized in that the window receiving space is set up as part of the cavity and serving as a limitation of the window receiving space structural component in this area no openings to the passenger compartment facing side of the vehicle door.

7. Vehicle door according to one of claims 5 or 6, characterized in that the cavity is designed to be open to the outside of the vehicle door, so that easy assembly and service work on an attachment are feasible.

8. Vehicle door according to one or more of the preceding claims, characterized in that all required attachments such as hinges, door brake, lock, window frames, seals, speakers, wiring harness, door trim over the Structural component, in particular screwed, clipped, glued and / or inserts are fastened.

9. Vehicle door according to one or more of the preceding claims, characterized in that on the inside of the structural component, an inner component such as a door handle and / or an armrest and / or a map pocket directly or via a door trim on the structural component can be fastened.

10. Vehicle door according to one of the preceding claims, characterized in that for the electrical supply of the attachments located in the door ribbon conductor and / or flexible printed boards (insulating film with conductive layer) are provided and these are secured in a suitable manner to the structural component.

11. Vehicle door according to one of the preceding claims, characterized in that the structural component for noise reduction, in particular for better absorption of disturbing noises, preferably on the inside of the cavity, one or more openings.