DE102013006367A1 - Method for connecting hybrid component to connection element in hollow chamber structure for body of motor vehicle, involves joining hybrid component with connection element in connection area through laser welding in reinforcement area - Google Patents

Abstract

The method involves joining a hybrid component (3) with a connection element (13) in a connection area (15) through laser welding in a reinforcement area (12), where the connection element is made from metal. The connection area is connected with a contact surface (19) of a metallic base body (5), where the contact surface is arranged in the reinforcement area. Laser radiation of a welding laser is aligned on a side surface (25) of the connection area, where the side surface is turned away from the contact surface. An independent claim is also included for a structural element.

Description

The invention relates to a method for connecting a hybrid component to a metal-comprising connecting element according to the preamble of claim 1, a structural element according to the preamble of claim 7, and a motor vehicle shell structure according to the preamble of claim 10.

In particular, in the bodywork for motor vehicles are increasingly hybrid components use, which have a metallic body, wherein in a gain region typically on one side of the body, a non-metallic reinforcing element is arranged. Such a hybrid component is for example from the German patent application DE 10 2009 009 112 A1 out. The reinforcing element, also referred to as a patch, typically consists of fiber-reinforced plastic, in particular of glass fiber reinforced or carbon fiber reinforced plastic. It is glued or pressed into the reinforcement area of the metal base for local reinforcement. The metallic base body typically comprises steel or a light metal, in particular aluminum. Due to the local reinforcement of the hybrid component by the reinforcing element, which is typically specific lighter than the metallic base body, it is possible to significantly reduce the wall thickness of the base body compared to a purely metallic construction. In total, this saves weight.

Especially in the body shop, the problem arises that such hybrid components must be joined with conventional metallic components. It turns out that in the reinforcement area no connection by means of conventional joining methods is possible, which require a bilateral accessibility of the joint. Namely, the metallic base body is accessible only from one side, while on the other side thereof the non-metallic reinforcing element is arranged. As a result, in particular common welding processes are ruled out for joining. However, in order to be able to use conventional joining methods, the hybrid component is joined in the region of an edge with a conventional metallic component, wherein no reinforcing region is provided in the edge region. However, if a joining in the reinforcing region is required, the reinforcing element is recessed in a joining region, so that locally conventional joining techniques can be applied here. As a result, however, the structure of the hybrid component in the region of the recess is disadvantageously weakened.

The invention has for its object to provide a method, a structural element and a motor vehicle shell structure, said disadvantages do not occur. In particular, it should be possible to add the hybrid component with a connection element in the gain range, without this being weakened adversely.

The object is achieved by providing a method with the steps of claim 1. In this case, a hybrid component is joined to a connection element, the connection element consisting of metal, at least in a connection region in which it is joined to the hybrid component. The method is characterized in that the hybrid component is joined by laser welding in the reinforcement region with the attachment element. By laser welding, it is possible to effect a connection of the hybrid component to the connecting element securely and firmly even in the reinforcing region, without the reinforcing element having to be recessed. In this way, despite the connection in the reinforcing region, no weakening of the reinforcing element and thus of the hybrid component or the entire structure to be formed is caused. Rather, this retains its stability even during and after joining.

It is possible that a connection element is used, which is designed as a conventional structural element, wherein it consists entirely of metal, preferably of light metal. Alternatively, it is possible that a connection element is used which at least partially comprises materials other than metal, in particular non-metallic materials. In particular, it is also possible that the connection element is designed as a hybrid component, wherein two hybrid components are joined together in the context of the method, wherein the one hybrid component in the gain region and the other hybrid component in a non-reinforced connection region, which consists of metal, on the respectively other part is attached. Thus, the connection region of the attachment element which consists of metal, that is to say comprises no other materials, in particular no reinforcement element, is connected to the reinforcement region of the hybrid component, wherein the reinforcement region comprises both the metallic base body and the non-metallic reinforcement element.

In the context of the method results in an optimal connection of the hybrid component to the connection element, in particular to a surrounding structure of a motor vehicle body. This results in no weakening of the structure by recess of the reinforcing element or by a possibly undesirable distance thereof from an edge of the body, which is provided only for joining. Rather, can be completely dispensed with such a distance, because no purely metallic area on the side of the hybrid component is required for connection to the connection element. The reinforcing element can therefore be provided up to the edge of the base body.

A method is preferred which is characterized in that the connection region with a first side surface is brought into contact with a contact surface of the metallic base body arranged in the reinforcement region. In this case, a laser beam of a welding laser is directed to a second side surface of the connection region facing away from the contact surface. The connection region of the connection element thus has two side surfaces, of which a first is brought into contact with a contact surface of the metallic base body. Also, the metallic base body has two side surfaces, namely the contact surface and a reinforcing surface facing away from this, on which the reinforcing element is arranged. Thus, two metallic surfaces are brought into contact with each other, wherein the reinforcing element is provided on the reinforcing surface, which faces away from the contact surface and thus the first side surface of the connection region. The second side surface of the connection region faces away from the contact surface. On this the beam of the welding laser is directed.

A method is preferred which is characterized in that, starting from the second side surface of the attachment element, it is welded into the metallic base body of the hybrid component. In this case, the reinforcing element arranged on the reinforcing surface is not damaged. A laser beam welding operation is therefore preferably carried out, wherein from the second side surface through the connection region of the connection element is welded into the metallic base body of the hybrid component. In this case, the penetration depth of the laser beam-preferably determined by a laser power, a beam diameter, a pulse duration of a pulse laser and / or other parameters of the laser beam-is chosen such that neither the laser beam nor preferably a region of the metallic base body melted during welding into the region of the reinforcement element penetrates. This is therefore not affected by the laser welding, in particular not damaged. Optionally, a shortest distance of a deepest penetration point of a welding point or a weld from the reinforcing surface is chosen so that the reinforcing element is not thermally loaded in a manner that could lead to damage.

Laser beam welding provides a fast and cost effective method by which large numbers of hybrid components and fasteners can be joined together, with short cycle times being feasible.

A method is also preferred which is characterized in that at least one spot weld is produced by means of the laser beam. It is thus possible to carry out a spot welding in the context of the method or to address the hybrid component to the connecting element. Alternatively or additionally, at least one weld seam is preferably produced by means of the laser beam. For this purpose, preferably a relative movement between the assembly to be joined from the hybrid component and the connection element on the one hand and the laser beam on the other hand causes, so that it can generate along its displacement path a weld. It is also possible for the laser beam to generate a number of spaced spot welds along a displacement path.

The laser used is preferably a pulsed laser or a continuous wave laser.

A method is also preferred which is characterized in that a hollow chamber structure is produced. It is possible that a shell-shaped hybrid component and / or a cup-shaped attachment element is / are used. In a preferred embodiment of the method, these are joined together in such a way that a hollow chamber structure surrounded by the connection element on the one hand and the hybrid component on the other hand is formed. In a particularly preferred embodiment of the method, the hybrid component is arranged in a cavity between two connection elements. In this case, it is joined with at least one of the attachment elements, preferably with both attachment elements. Preferably, at least one of the connection elements is designed shell-shaped. Particularly preferably, both attachment elements are formed shell-shaped. Additionally or alternatively, it is possible that the hybrid component is formed cup-shaped.

A method is also preferred that is characterized in that a structural element is produced for a bodyshell structure of a motor vehicle body. In this case, the structural element is produced from at least one hybrid component and at least one attachment element by joining the hybrid component and the attachment element to one another. This makes it possible to operate in the framework of the bodyshell structure of the motor vehicle body lightweight, with considerable weight potentials and ultimately a significant fuel economy is possible. In particular, when the structural element is formed as a hollow-chamber structure, a sill, an A-pillar, is preferably introduced in the manner mentioned Roof frame, a longitudinal beam, a tunnel, a cross member or another, corresponding structural element of a motor vehicle body manufactured, which is manufactured in particular in shell construction.

The object is also achieved by providing a structural element with the features of claim 7. The structural element, which is provided in particular for a body shell of a motor vehicle body, has at least one hybrid component which comprises a metallic base body and at least one non-metallic reinforcing element arranged on one side of the base body in a reinforcing region. It also has a connection element, which consists of metal at least in a connection region. The structural element is characterized in that the hybrid component is joined by laser welding in the reinforcement region with the attachment element in its connection region. Particularly preferably, the structural element is produced by a method according to one of the previously described embodiments. Thus, the advantages that have already been explained in connection with the method result.

A structural element is preferred, which is characterized in that the connecting element consists entirely of metal. Preferably, the connection element consists of a light metal, particularly preferably of aluminum, magnesium, an aluminum alloy, or a magnesium alloy. The connection element is formed in a preferred embodiment as a conventional component of a motor vehicle shell structure and is combined with at least one hybrid component as part of the body construction.

The attachment element and / or the metallic base body of the hybrid component is / are preferably manufactured in sheet metal and / or shell construction, and thus formed in particular as a formed, in particular deep-drawn sheet metal.

Alternatively, it is preferred that the attachment element comprises at least one additional material other than metal. In particular, it is also possible in a preferred embodiment that the connection element is formed as a hybrid component, wherein it has a connection region in which no reinforcing element is arranged. Rather, the connection area consists entirely of metal.

It is also preferred a structural element, which is characterized in that the hybrid component has a shell structure. Alternatively or additionally, it is preferred that the attachment element has a shell structure. As an alternative or in addition, the structural element is preferably designed as a hollow-chamber structure. This may for example be the case when a shell-shaped hybrid component is joined to a connection element, or when a shell-shaped attachment element is joined to a hybrid component, or when a shell-shaped attachment element is joined to a shell-shaped hybrid component, wherein in each of these embodiments, preferably the hybrid component and the Connecting element limit a cavity. In a particularly preferred embodiment, the hybrid component is arranged in a cavity between two attachment elements, wherein it is joined with at least one of the attachment elements. In this case, preferably at least one of the connection elements is designed shell-shaped. Preferably, both attachment elements are formed shell-shaped. Alternatively or additionally, it is possible that the hybrid component is also shell-shaped.

Finally, the object is also achieved by providing a motor vehicle bodyshell structure having the features of claim 10. This is characterized by a structural element according to one of the embodiments described above. This results in the advantages that have already been described in connection with the method and the structural element.

It can be seen that, in particular, the description of the method and the structural element are to be understood as complementary to one another. In particular, a structural element is preferred which is characterized by at least one feature which is determined by at least one method step, preferably combinations thereof, of the method. Conversely, an embodiment of the method is preferred, which is characterized by at least one method step, which is due to at least one feature, preferably combinations thereof, of the structural element. In this respect, features described in connection with the method are preferably individually or in combination with each other features of a preferred embodiment of the structural element. Conversely, method steps described in connection with the structural element are preferably individually or in combination with one another preferred steps of a preferred embodiment of the method.

The invention will be explained in more detail below with reference to the drawing. Showing:

1 a schematic sectional view of a first embodiment of a structural element;

2 a schematic sectional view of a second embodiment of a structural element, and

3 a schematic sectional view of a third embodiment of a structural element.

1 shows a schematic sectional view of a first embodiment of a structural element 1 , This has a hybrid component 3 on which a metallic base body 5 includes. The metallic base body has two sides, wherein it is cup-shaped in the illustrated embodiment and in this respect a concave inner side 7 and a convex outside 9 having. In the illustrated embodiment is on the concave inside 7 a reinforcing element 11 in a reinforcement area 12 arranged. The convex outside 9 has no reinforcing element. The reinforcing element 11 is so far on one side of the metallic body 5 arranged.

The metallic base body 5 is preferably made of a light metal or a light metal alloy, in particular of aluminum or an aluminum alloy, or of magnesium or a magnesium alloy. It is also possible that the metallic base body 5 made of steel.

The reinforcing element 11 preferably consists of a fiber-reinforced plastic, in particular carbon fiber reinforced plastic or glass fiber reinforced plastic. It is preferably with the main body 5 glued or pressed, especially in the body 5 glued or pressed in.

The structural element 1 also has a connection element 13 on, this is a connection area 15 for connection of the hybrid component 3 includes. There is the connection element 13 at least in the connection area 15 of metal or a metal alloy, preferably of steel, or of a light metal or a light metal alloy, in particular of aluminum or an aluminum alloy, or of magnesium or a magnesium alloy. The connecting element preferably exists 13 altogether from one of the mentioned materials.

Preferably, it is both in the hybrid component 3 as well as the connection element 13 to components for a motor vehicle shell structure. Here is the connection element 13 preferably designed as a conventional or conventional component of a motor vehicle body. In another embodiment, however, it is possible that the connection element 13 is also designed as a hybrid component, but it is in the connection area 15 completely made of metal.

The connection area 15 has a first side surface 17 on, which is in contact with a contact surface 19 of the metallic body 5 in the reinforcement area 12 is arranged. Accordingly, the metallic base body 5 one of the contact surface 19 opposite reinforcing surface 21 on, at which the reinforcing element 11 is arranged.

In 1 is a weld 23 shown in cross-section, that of a second side surface 25 here in the connection area 15 is introduced, wherein the second side surface 25 the contact surface 19 turned away. In another embodiment, a welding point may be provided.

The weld 23 is used in the process from one to the second side surface 25 directed laser beam introduced. In particular, from the second side surface 25 out through the connection area 15 in the metallic body 5 welded, with the weld 23 not so deep enough that the reinforcing element 11 would be affected.

Preferably, the weld extends 23 perpendicular to the image plane of 1 , wherein preferably by a relative displacement of the structural element 1 and the laser beam is generated perpendicular to the image plane of 1 runs.

It turns out that the hybrid component 3 and the connection element 13 on the one hand in the reinforcement area 12 and, on the other hand, in the connection area 15 together through the weld 23 this is possible by means of the method, although in the reinforcing region 12 the reinforcing element 11 is arranged. This need not be cut out or recessed because there is no accessibility of the reinforcing surface to perform the method 21 requirement. This also makes the reinforced structure of the hybrid component 3 not partially weakened. This therefore retains its complete stability during and after the joining process.

In particular, it is apparent from 1 that it is possible the hybrid component 3 almost in the middle of the amplification area 12 with the connection element 13 to add. The joint does not have to be on an optionally unreinforced only for this purpose edge of the hybrid component 3 be laid, as it - as an alternative to a recess of the reinforcing element 11 - Is the case with known methods.

2 shows a schematic sectional view of a second embodiment of a structural element 1 , Identical and functionally identical elements are provided with the same reference numerals, so that reference is made to the preceding description. In this embodiment, it turns out that the reinforcing element 11 close to a border 27 . 27 ' of the metallic body 5 may be provided, where it is possible, this right up to the edge 27 . 27 ' let it pass, or even over the edge 27 . 27 ' to survive. Nevertheless, it is possible in the area of the edge 27 . 27 ' Joining connections to the connection element 13 provided. In the illustrated embodiment, the connection element 13 cup-shaped and has two connection areas 15 on. These are by means of the method and by means of a weld 23 with the hybrid component 3 together. In this way is a cavity 29 designed so that the structural element 1 is formed overall as a hollow chamber structure.

3 shows a schematic sectional view of a third embodiment of a structural element 1 , Identical and functionally identical elements are provided with the same reference numerals, so that reference is made to the preceding description. The embodiment of the structural element 1 is designed as a hollow chamber structure, in which case two connection elements 13 . 13 ' are arranged to each other such that between them a first cavity 29 results. Preferably, the two connection elements 13 . 13 ' in a conventional manner, for example by welding, soldering, gluing, riveting, screwing or otherwise joined together. Here is the connection element 13 designed as a cup-shaped element. It therefore has a shell structure.

In the first cavity 29 is a hybrid component 3 arranged here in particular in connection with 1 described in detail by two welds 23 with the connection element 13 is added. In the illustrated embodiment, the hybrid component 3 not with the second attachment element 13 ' together. In another embodiment, it is possible that the hybrid component 3 both with the first attachment element 13 as well as with the second connection element 13 ' is added. For this purpose, the described method can be used. It is alternatively or additionally possible that the hybrid component 3 in areas where it is made of metal, ie not as a reinforcement area 12 are formed, in a conventional manner with one of the connection elements 13 . 13 ' is added.

In the illustrated embodiment, the hybrid component close 3 and the second attachment element 13 ' together with a second cavity 31 one. Characterized in that in the context of the method, a connection of the first connection element 13 with the hybrid component 3 virtually from the outside by welding takes place, it is easily possible, the hybrid component 3 in the first cavity 29 between the connection elements 13 . 13 ' to arrange and to add there. It is particularly possible, first the connection elements 13 . 13 ' with each other and then before or after in the first cavity 29 introduced hybrid component 3 with at least one of the connection elements 13 . 13 ' to add from the outside. This requires no access to the first cavity 29 or to the second cavity 31 ,

Overall, it is found that it is possible with the help of the method, the structural element and the motor vehicle shell structure, effective, cost-effective, in large numbers and with short cycle times to provide a connection of hybrid components, especially for the automotive lightweight construction, with no weakening of reinforcing structures are accepted got to. Here are also hollow chamber structures, for example, for sills, A-pillars, roof frames, side members, tunnels, cross members and other corresponding elements readily representable.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102009009112 A1 [0002]

Claims (10)

Method for connecting a hybrid component ( 3 ) to a metal-containing attachment element ( 13 ), wherein a hybrid component ( 3 ), which has a metallic base body ( 5 ) and at least one in a gain region ( 12 ) on one side of the base body ( 5 ), non-metallic reinforcing element ( 11 ), with a connection element ( 13 ), which at least in one connection area ( 15 ) is made of metal, characterized in that the hybrid component ( 3 ) by laser welding in the reinforcement region ( 12 ) with the connection element ( 13 ) in its connection area ( 15 ) is added. Method according to claim 1, characterized in that the connection area ( 15 ) with a first side surface ( 17 ) in contact with one in the gain region ( 12 ) arranged contact surface ( 19 ) of the metallic base body ( 5 ), wherein a laser beam of a welding laser on one of the contact surface ( 19 ) facing away, second side surface ( 25 ) of the connection area ( 15 ). Method according to one of the preceding claims, characterized in that from the second side surface ( 25 ) of the connection element ( 13 ) out into the metallic base body ( 5 ) of the hybrid component ( 3 ) is welded, without that on one of the contact surface ( 19 ) facing away from reinforcing surface ( 21 ) arranged reinforcing element ( 11 ) is damaged. Method according to one of the preceding claims, characterized in that by means of the laser beam at least one welding point or at least one weld ( 23 ) is produced. Method according to one of the preceding claims, characterized in that a hollow chamber structure is produced, wherein preferably the hybrid component ( 3 ) in a cavity ( 29 ) between two connection elements ( 13 . 13 ' ) and with at least one of the connection elements ( 13 . 13 ' ) is added. Method according to one of the preceding claims, characterized in that a structural element ( 1 ) is manufactured for a shell structure of a motor vehicle body. Structural element ( 1 ), in particular for a shell of a motor vehicle body, with at least one hybrid component ( 3 ), which has a metallic base body ( 5 ) and at least one in a gain region ( 12 ) on one side of the base body ( 5 ), non-metallic reinforcing element ( 11 ) and with a connection element ( 13 ), which at least in a connection area ( 15 ) is made of metal, characterized in that the hybrid component ( 3 ) by laser welding in the reinforcement region ( 12 ) with the connection element ( 13 ) in its connection area ( 15 ), the structural element ( 1 ) is preferably prepared by a method according to any one of claims 1 to 6. Structural element ( 1 ) according to claim 7, characterized in that the connection element ( 13 ) made of metal, preferably of light metal. Structural element ( 1 ) according to one of claims 7 and 8, characterized in that the hybrid component ( 3 ) and / or the connection element ( 13 ) has / has a shell structure and / or that the structural element ( 1 ) is formed as a hollow chamber structure, wherein preferably the hybrid component ( 3 ) in a cavity ( 29 ) between two connection elements ( 13 . 13 ' ) and with at least one of the connection elements ( 13 ) is added. Motor vehicle body shell structure, characterized by a structural element ( 1 ) according to any one of claims 7 to 9.

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