DE102008017976A1 - Side wall for passenger car body, has column areas partially made of cast material, where adjacent assembly area, proceeding in vehicle longitudinal direction, is connected with column area by recasting - Google Patents

Abstract

The side wall (10) has column areas (12,14,16) proceeding in the vehicle vertical direction and assembly areas (18,20,22,24,30,32) proceeding in vehicle longitudinal direction. The column areas are partially made of cast material. An adjacent assembly area, proceeding in vehicle longitudinal direction, is connected with the column area by recasting. Independent claims are also included for the following: (1) a method for manufacturing a side wall of a passenger car body (2) a mold for use in a method for manufacturing a side wall of a passenger car body.

Description

The Invention relates to a side wall of a frame structure of a motor vehicle, which consists of cast components and profile components.

For the construction of self-supporting vehicle bodies in lightweight construction usually a profile construction is chosen, in which individual profile components via cast nodes with each other are connected. The cast nodes and the profile components are doing over usual Joining methods interconnected. To such conventional To allow joining of the used components often have to be complex trained on these components Be provided joining surfaces.

These Conventional method for building frame structures is with a number of disadvantages. Especially when joining of profile components and casting nodes by welding arise in the area of the connections between the components in the course of the welding process unfavorable material changes. That's why for the formation of so-called heat affected zones, in which by the high temperature used during the welding process changed the lattice structure of the materials used is. As a result, it is precisely in the area of such joining zones to the occurrence of particularly high material tensions, which is the quality impaired connections and long-term stability the frame structure is reduced.

The achievable manufacturing tolerances in the production of such frame structures are still adversely affected by the used Joining process limited. The positioning of the items before welding or gluing is expensive, and requires the introduction of additional process engineering Steps.

In order to enable a better positioning of profile elements in their spatial relationship with the casting nodes, is in the DE 199 31 741 A1 discloses a lightweight construction of a motor vehicle, wherein in the castings of a body part molding pockets are provided, in which then the profile components of the body can be fixed.

In the WO 96/39322 is further disclosed a method for joining structural components, in which elongate structural elements are inserted into a mold, and encapsulated with a casting material.

Of the present invention is based on the object, a side wall a frame structure of a motor vehicle available which consists of cast components and profile components, and which Process technology is particularly easy to manufacture and at the same time a high stability as well as a high quality having the connections between cast components and profile components.

These Task is solved by a side wall with the features of claim 1

at a side wall according to the invention for the frame structure of a motor vehicle are parallel to the vehicle's vertical axis extending components, in particular the columns of the frame structure as Cast components executed. Furthermore, the parallel to the Vehicle longitudinal axis extending components as profile components executed, which cohesively by casting are connected to the cast components.

By Such an embodiment according to the invention a sidewall becomes an optimal compromise between stability and weight of the frame structure in the area of the side wall. occurring Forces are from the in vehicle longitudinal direction extending profile components and added to the casting node of Led columns of the side wall, from where a force transmission For example, on the roof frame or the cross member of the Floor group is possible.

By the Umgießen running in the vehicle longitudinal direction Profile components becomes a larger area when joining the structure and even heat input from the Casting compound in the profile components allows the training of heat affected zones and thus a quality-reducing Change of the lattice structure of the metal of the profile components in Area of the joining zones is thus avoided. By the pre-positioning the profile components in corresponding recesses of the mold for the sidewall is also an accurate production possible with low tolerances.

In In a particularly preferred embodiment, the in Lengthwise of the vehicle running profile components as Extruded profiles and / or sheet metal components designed. Strength, Weight and connection stiffness of the profile components can thereby optimal for each individual position to each there be adjusted to the effective force entries.

The invention further comprises a method for producing a side wall for the body of a passenger car, which has the features of claim 1. Instead of pre-assembled individual prefabricated components, it is possible by such a method according to the invention to produce such a side wall in a process-technically simple manner. Prefabricated profile components only have to be inserted into recesses provided in a casting mold, and are then cast in a single process step, at least in their end regions with molten metal. The manufacturing tolerances in the manufacture of such a sidewall can be considerably reduced by this method.

to Implementation of the method according to the invention According to claim 3 is used in claim 4 described mold. Such a mold contains a plurality of each other separate cavities for casting the substantially in the vertical direction extending column areas, as well as a Plurality of recesses for inserting in the vehicle longitudinal direction extending profile components. By using a single mold for the complete sidewall can be up Advantageously, the production processes as streamlined as possible and easy to design.

In A preferred embodiment is each cavity the casting mold assigned its own sprue device, via the cavity through a casting device with molten metal can be sent. This makes it possible to use the Alloy, as well as the pressure conditions used for the Cast each individual casting node of the vehicle sidewall separately to optimize. An optimal adaptation of the individual cast components to the forces acting on each of them is thus made possible.

in the The invention is based on the drawings, the invention without limitation the general public are explained in more detail, wherein

1 shows a schematic view of a side wall of a frame structure according to the invention, and

2 shows a cross section through a used for producing such a side wall mold.

A whole with 10 designated frame structure for a side wall of a motor vehicle consists of three running in the vehicle vertical direction casting components, namely the A-pillar 12 , the B-pillar 14 and the C-pillar 16 , A lateral side member 18 as well as a roof frame carrier 20 connect the three pillars 12 . 14 . 16 to a closed frame. The carriers 18 . 20 are designed as extruded aluminum profiles.

Towards the front of the vehicle, the cast component for the A pillar continues to be an upper side member 22 and a lower side member 24 cast. Between the side rails 22 and 24 is a pickup element 26 for receiving a shock absorber leg, as well as a steering axle provided. In the front area of the carrier 22 and 24 Furthermore joining surfaces are provided for connecting a front module of a motor vehicle.

The cast component for the C-pillar 16 extends to the rear of the vehicle further in the vehicle longitudinal direction and forms in its lower part 28 a structure for receiving a rear shock absorber leg and a rear vehicle axle. Furthermore, an upper rear side member 30 and a lower rear side member 32 by encapsulation cohesively with the C-pillar 16 connected. In the vehicle rear end region of the side members 30 and 32 In this case joining surfaces are provided for connecting a rear module of the motor vehicle.

In addition to the supporting function as part of the vehicle frame meets the in 1 on top of that, further functions in the connection of other components of the motor vehicle body. So are at A-pillar 12 and B-pillar 14 Shooting for the column-side part of the door hinges 34 . 34 ' cast together. Furthermore, joint surfaces for connecting a vehicle outer paneling, as well as joint areas for receiving transverse to the vehicle transverse direction, in all the described components 1 not shown cross members of the roof and floor structure available.

2 shows a cross section through a casting device for a vehicle side wall according to the invention. The casting device comprises a first cavity 36 which cast the A-pillar 12 the sidewall serves a second cavity 38 which cast the B-pillar 14 serves, as well as a third cavity 40 which cast the C-pillar 16 and the rear strut mount 28 is trained.

Between the cavities are in the vehicle longitudinal direction exceptions 42 for receiving the lateral side members 18 as well as recesses 44 for receiving the roof frame girders 20 intended. Furthermore, the mold comprises recesses 46 , which for receiving the front upper side member 22 , the front lower side member 24 , as well as the front strut mount 26 serves, as well as recesses 48 and 50 , which for receiving the rear lower side member 32 and the rear upper side member 30 serve.

In a first method step in the manufacture of a vehicle side wall according to the invention, the corresponding profile or sheet metal parts are inserted into these recesses. Once the parts are positioned, the mold is made with the help of the locking devices 52 pressure sealed, and connected to a casting device. Each of the cavities 36 . 38 and 40 is a separate sprue device 54 . 54 ' . 54 '' associated so that the three cavities can be filled separately with a liquid metal alloy. By means of this separate filling, it is possible to use different metal alloys or different casting conditions for the individual columns of the side wall structure, and nevertheless to manufacture the entire side wall according to the invention in a single casting step. After cooling and curing of the cavities 36 . 38 and 40 pressed melt, the mold can be reopened, and the finished vehicle sidewall 10 be removed.

10

frame structure

12

A column

14

B-pillar

16

C-pillar

18 22, 24

longitudinal beams

20

Roof frame carrier

26

front wheel carrier

28

Strut support

30 32

longitudinal beams

34 34 '

door hinges

36 38, 40

cavity

42

exceptions

44 46, 48, 50

recesses

52

closure device

54 54 ', 54' '

Angus device

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 19931741 A1 [0005]
• WO 96/39322 [0006]

Claims (5)

Side wall ( 10 ) for a body of a passenger car, which at least substantially in the vehicle vertical direction extending column areas ( 12 . 14 . 16 ) and at least substantially in the vehicle longitudinal direction extending component areas ( 18 . 20 . 22 . 24 . 30 . 32 ), characterized in that the column areas ( 12 . 14 . 16 ) are at least partially made of cast material, wherein at least one adjacent, at least substantially extending in the vehicle longitudinal direction component area ( 18 . 20 . 22 . 24 . 30 . 32 ) by encapsulation cohesively with the casting material designed column areas ( 12 . 14 . 16 ) connected is. Side wall according to claim 1, characterized in that the component areas extending substantially in the vehicle longitudinal direction ( 18 . 20 . 22 . 24 . 30 . 32 ) are designed as extruded profiles and / or sheet metal components. Method for producing a side wall for a body of a passenger car, which comprises at least substantially pillar regions extending in the vehicle vertical direction (US Pat. 12 . 14 . 16 ) and at least substantially in the vehicle longitudinal direction extending component areas ( 18 . 20 . 22 . 24 . 30 . 32 ), characterized in that the column areas ( 12 . 14 . 16 ) are at least partially made of cast material, wherein at least one adjacent, at least substantially extending in the vehicle longitudinal direction component area ( 18 . 20 . 22 . 24 . 30 . 32 ) by encapsulation cohesively with the casting material designed column areas ( 12 . 14 . 16 ) is connected. Mold for use in a method according to claim 3, characterized in that a plurality of separate cavities ( 36 . 38 . 40 ) for casting the column areas extending substantially in the vehicle vertical direction ( 12 . 14 . 16 ), as well as a plurality of recesses ( 44 . 46 . 48 . 50 ) for inserting the components for the component regions extending essentially in the vehicle longitudinal direction ( 18 . 20 . 22 . 24 . 30 . 32 ) are provided. Mold according to claim 4, characterized in that each cavity ( 36 . 38 . 40 ) of the casting mold a sprue device ( 54 . 54 ' 54 '' ), via which the cavity can be charged by a casting device with molten metal.