WO2012076078A1 - Body of a passenger motor vehicle and method for repairing such a body - Google Patents

Abstract

The invention relates to a body of a passenger motor vehicle, comprising a plurality of body components (10-14) which are connected to each other and are at least partially provided with a plastic material (24). A plurality of predefined repair joints (28-34) are provided on the body, where a body component (38-46) that has been deformed as a result of an accident can be separated from the rest of the body. The invention further relates to a method for repairing such a body.

Description

 Body of a passenger car and procedure

 to repair such a body

The invention relates to a body of a passenger car specified in the preamble of claim 1. Art. Furthermore, the invention relates to a method for repairing such a body according to the preamble of claim 6.

In production vehicle production for passenger cars, a plurality of body components are usually connected to one another, for example by means of welded or glued connections, for producing the vehicle structure. It is also known to provide individual body parts of the body with a plastic, so that they are designed as hybrid components. Such hybrid components come

For example, in instrument carriers, door carriers or other carrier components used.

In such bodies, there is usually the problem that the repair of accidental deformations of the body is usually extremely expensive.

Object of the present invention is therefore to provide a body of a

Passenger car as well as to provide a method for repairing such a body of the type mentioned, by means of which can be significantly simplify the repair in case of damage.

This object is achieved by a body of a passenger car and by a method for repairing such a body with the features of claims 1 and 6 respectively. Advantageous embodiments with expedient and non-trivial developments of the invention are specified in the remaining claims. To create a body of the type mentioned above, which can be repaired in a simpler manner in the event of damage, a plurality of predetermined repair partitions are provided on the body according to the invention, on which a correspondingly accidentally deformed body part from the rest of the body is separable. Thus, it is provided according to the invention to define a plurality of repair partitions on the body, wherein a damaged body part is then separated from the rest of the body that the respective

Bodywork components at the appropriate repair centers, which the

isolate damaged body part, be separated. This has the advantage that body parts intended for repair, which are intended to replace the respective body part which has been deformed as a result of the accident, can be pre-assembled accordingly. Thus, this no longer needs to be done in the workshop, with the risk that an unfavorable repair separation point is selected, or for example, too little overlap between the newly attached body part and adjacent

Body parts of the rest of the body. It also results in a simpler

Production and logistics of spare parts.

In a further advantageous embodiment, it is provided that a thermoplastic material is used at least in the region of the corresponding repair partitions. This has the advantage, for example, that in the repair of the body or when inserting a new body part of the plastic in the field of

Repair separation points in a simple manner by heating, for example by

Welding or hot air forming, can be used to add the two adjacent body panels.

It is also advantageous if a repair body part is provided which has a respective overlap with the rest of the body in the area of the separated repair partitions. This overlap can be due to the

Prefabricated the respective repair body part or due to the defined position in the corresponding repair separation points at which the accidentally deformed body part is cut out, are selected so that the necessary strength and rigidity in the field of repair centers is achieved.

Preferably, these overlaps are oversized to achieve a corresponding strength or rigidity.

If the body further has respective connection points for cable sets or the like, which are located in the area of a repair separation point and / or in the region of a Connection component are provided, it can, for example, an accidentally deformed body part or the entire body are replaced without the complete wiring set must be removed before. Rather, can then be used in the repair body part or in the entire body integrated cable sets, which deformed when replacing an accident

Body part or the entire body can be connected to the respective connection parts with the adjacent lines.

Finally, it has been found to be advantageous when the bodywork

Has damage detection system. Thus, in a simple way

Damage can be determined in good time, because in addition in particular the location of the damage can be determined in a simple manner. Thus, it can be evaluated in a simple way, how big the damage is and which parts or areas of the body must be built or repaired.

The advantages explained above in connection with the body according to the invention also apply to the method for repairing a body according to

Claim 6.

This is characterized according to claim 9 further characterized in that in the region of a deformation point, an additional body part is added to the body. This can be done for example by mechanical means or by a joint connection, wherein the plastic of the body can be used in addition to the joining of the additional body part with the body.

Finally, it has proven to be advantageous if in the region of a deformation point, a hot forming, in particular a hot air forming, of the thermoplastic material of the body is made. Smaller damage can thus be at least partially repaired.

Further advantages, features and details of the invention will become apparent from the following description of preferred embodiments and from the drawings; these show in:

Fig. 1a, 1b is a schematic front view and a schematic

Side view of a body of a passenger car with a plurality of interconnected body parts, which are at least partially provided with a plastic or connected to each other via this;

Fig. 2 is a partial perspective side view of the

 Body according to FIGS. 1a and 1b, which comprises a plurality of predetermined repair partitions, which a correspondingly accidentally deformed body part from the rest of the body is separable, so that to the rest of the body of one shown in exploded view

 Repair body parts is attachable, which has a respective overlap with the rest of the body in the area of the separated repair separation point;

Fig. 3 shows a further side view of the body according to Figs. 1a to 2, in turn, each repair partitions are recognizable, in which an accidentally deformed body part of the rest of the body is separable and also in

 Side view illustrated repair body part is attachable;

4a, 4b, 4c, 4d is a schematic sectional view of a body part to

 Explanation of the repair by means of another body part, a sequence of six representations, the

 Securing process of a fiber-saving self-forming screw for screwing into a formed on the fiber composite plastic part body part represents, another sectional view through a body part to explain a possible

 Connecting a repair body part to a body part of the original body and respective sectional views through a body part to explain the repair by hot working;

Fig. 5 is a perspective view of the body according to FIGS. 1a to 3, wherein a plurality of wiring sets are integrated into the body, which respective connection points in the region of

have associated repair separation point and / or in the region of a connection component; and in 6 shows a perspective view of the body according to FIGS. 1 a to 3, wherein a damage detection system with a plurality of sensors integrated into the body can be seen.

A bodywork for a passenger car is shown in FIGS. 1a and 1b in a schematic front view and a schematic side view, respectively. In the present case, this is a two-seat vehicle in Einvolumenform, the invention described below could also be used in other types of motor vehicle bodies. Foreign body parts are visible in Fig. 1: A rear frame profile 10, a respective side frame profile 12 and a respective side sill profile 14. These body parts 10, 12, 14 are each designed as hydroforming Spritzgießbauteile in the manner described in more detail below. Furthermore, a plastic-coated bottom plate 16, a plastic-coated front side structure plate 18, can be seen

plastic-coated rear side structure panel 20 as well as a

Roof frame receiving trained gusset plate 22nd

The body components 10 to 22 may thus essentially be tubular or hollow profiles or planar elements such as sheet steel, light metal or based on a dry textile as well as organo sheets or the like. It is even conceivable, the tubular or hollow profiles of a FRP (fiber composite material),

in particular to produce CFRP.

The body components 10 to 20 are interconnected, for example, via hybrid connection nodes. These compounds could be produced, for example, mechanically by means of hydroclinics or other mechanical connection means, which are then at least partially provided with a plastic 24.

The peculiarity of the present body is to be seen in that

Essentially in a single tool and in one operation. This is done in this case in a combined hydroforming and

Injection molding in a plant, which respective facilities for

Hydroforming the body parts 10 to 20 and injection molding comprises. In this case, the body parts 10 to 20, for example, first arranged on a tool core, correspondingly transformed by hydroforming, joined together and, for example, by large-scale encapsulation with Plastic 24 provided. Thus, the body is preferably to be manufactured in a so-called "one-shot process." However, it is to be considered within the scope of the invention that other methods of production are also conceivable.

In Figs. 2 and 3, a body thus produced is a

Passenger car in a partial and perspective side view of a side wall 26 and in a schematic side view of the side wall 26 shown. This body is made in the manner described in connection with FIGS. 1a and 1b.

The peculiarity of this body is that at this a plurality of predetermined repair partitions 28, 30, 32, 34 are provided, on which a correspondingly accidentally deformed body part from the rest of the body is separable.

If, accordingly, a corresponding body part 38, 40, 42, 44, 46 is deformed in the event of an accidental application of force, then it is separated out, for example, at the next undamaged repair separation point (28-34). It is thus quite conceivable, for example, to separate two body parts 38 to 46, that is to say, for example, the adjacent body parts 42 and 44 from the rest of the body and then to replace them in a manner which will be described in more detail below.

In Figs. 2 and 3 are respectively in exploded view respective

Repair body parts 38 ', 40', 42 ', 44' and 46 'shown, through which the body part to be exchanged according to 38 to 46 can be replaced. If - as described above - a larger body part 38 to 46, so for example, the two body parts 42 and 44 should be cut out, the

Repair body parts 42 'and 44' either two-piece or else be designed in one piece.

Preferably, the respective repair body part 38 'to 46' has a respective overlap 48 with the body left over in the region of the respectively severed repair separation point 28 to 34. In other words, the repair body part 38 'to 46' is preferably designed to be larger than the separate body part 38 to 46, so that the corresponding overlap results in the area of the repair partitions 28 to 34. These overlaps will be there Oversized, so that the necessary strength and rigidity is present and optionally supplemented with repair connection elements.

Since the present body is essentially formed in one piece, it must also be decided on what level of damage to change the entire body. In addition, if the respective damage or accidental deformation in the area of a repair separation point 28 to 34, it must also be decided whether the damage can be repaired or if a complete replacement of the body is necessary. In the case of a total loss, the undamaged parts of the body can be used for repairing.

Below are now based on the Fig. 4a to 4d different repair and

Joining method shown by means of which a damage to the body repaired or a corresponding repair body part 38 'to 46' with the rest

Body can be connected.

First, it should be noted that there are several options, this

Repair bodywork damage. Through the use of thermoplastic

On the one hand, plastics 24 can with little damage the processes of

Hot forming, in particular the hot air forming or thermoforming and others are used for larger damage plastic welding. The welding of thermoplastics takes place in the high-viscosity state under application of pressure, whereby in this case the chain molecules of the plastic penetrate at the interfaces and should be entangled with each other. Preferably, only similar plastics are joined together. For example, the following processes can be considered for the welding of plastics:

Hot gas welding and extrusion welding

 Direct and indirect hot element welding

 frequency welding

 ultrasonic welding

 friction welding

 beam welding

From Fig. 4a, a body component 50 is first recognizable, which is designed as a component of the above-described body and consequently with

Fiber composite plastic 24 is provided. From Fig. 4a it can be seen that the Body component 50 has a corresponding deformation 52. This deformation in the form of a bead or denting is thereby repaired in the area of

Deformationsstelle 52 an additional body part 54 (repair patch) is added. This attachment can be made in particular by one of the above

Plastic welding connections done. Optionally, the deformation 52 may be cut in or out prior to the attachment of the body panel 54.

While in the present exemplary embodiment according to FIG. 4a, for example, the plastic 24, which is present anyway, of the body is used for fixing the body part 54, a joining technique combination can also be used

be made.

FIG. 4b shows a sequence of six method steps by one

Flow hole forming screw 56 in a corresponding body part 54 to screw. In process step 1, a heating of the sheet by a pressing force and a high speed, in step 2, the penetration of the material with the conical screw tip, in step 3, the molding of the cylindrical passage in step 4, the non-cutting grooves of the metric empty nut thread, in Step 5, the screwing and finally in

Process step 6 tightening the screw 56 with adjusted torque. Thus, this self-molding screw 56 in body or the fiber can be gentle on the fiber

Body part 54 are introduced.

In Fig. 4c can be seen how a damaged body part 50 is correspondingly separated at a corresponding separation point 58 and replaced by a repair body part 60 '. In the present case, this is done by a repair connection element 62, which is connected, for example, by gluing along a splice 64 to the body or the repair body 60 '. Optionally, also a

Overlapping be provided as described above. It is also conceivable to provide pop rivets and gluing in addition to gluing.

FIG. 4d shows, in a further sectional view in a sequence of method steps, the repair of a body part 60 by hot forming, in particular

Hot air forming, shown. A corresponding deformation 52 is heated according to method step 2 by heating the defective body part 60 and processed according to step 3 shaping. This benefits that the

Body part 60 optionally with a corresponding thermoplastic as a plastic 24 is provided. Dents can be pressed back into the correct shape as a result of heating. After cooling, the affected body part gets its old stability.

In addition, according to method step 4, a body component 50 can be attached to the body part 60 in the manner of the manner described in FIG. 4 a.

Overall, it can be seen that in this case a body or a method for repairing such a body is created, which allows a simple way to repair. First, it must be decided whether the existing damage is still worth repairing or if there is a total loss.

For the repair of the body, for example, to the normally required bodies additional repair bodies are made if necessary. These are stored centrally and their data stored, for example, the nature of their design using software tools. This tool will also repair instructions to the

Specialized workshops granted. These include instructions for cutting out the damaged parts. These instructions for the workshop for the robot cutting the parts in the factory are different from each other so that the described overlaps 48 for the later assembly of the respective repair body parts 38 'to 46', are present. The workshop enters the damage case and the exact location of the damage into the system and the software searches out the corresponding replacement body part, for example 38 'to 46'. In the

Repair software, the body is constructed as a kind of puzzle in which the puzzle pieces have a very specific shape, namely those of the repair body 38 'to 46', for example. Depending on the size of the damage, the software determines the optimum size for the repair body parts 38 'to 46'. This respective repair body part 38 'to 46' may have the size of a small sheet or a whole body side or may have an even larger configuration.

Fig. 5 shows a schematic perspective view of the body according to the above-described embodiment. When changing, for example, the side wall 26 or a side wall part of any attachments must be removed beforehand. These preliminary work must be done both in the conventional body as well as in the here described, provided with plastic 24 body, this effort or these processes are comparable to each other and feasible in both bodies. The much greater effort in a change of the body or a repair body part, for example, 38 'to 46', is the change respective Cable sets 68. To expose these cable sets 68, the complete

Interior fittings are removed.

For this reason, the line sets 68 in the present case have respective connection points 70 in the region of a corresponding repair separation point 28 to 34 and / or in the region of a connection component, for example a flap, hood or the like. With regard to increased Modulahtät can thus be the respective wiring set 68 on the body or the corresponding body component 38 'to 46' or the associated repair component 38 'to 46' preinstall or integrate. Thus, in the event of an accident-related change of the respective part, the respectively integrated line set 68 or the like can be easily connected via respective connection points 70 to respective line sets of preferably modular connection components such as door and tailgate. The connection points 70 can be formed in a simple manner as a plug connection. Thus, the

Reduce workshop visit to a minimum with a complete body change.

Fig. 6 finally shows the body analogous to Fig. 5, wherein a

Damage detection system with a plurality of sensors 66 in the body, in particular in the plastic 24, is integrated. The sensors 66 are arranged so as to be in time for particularly stressed or prominent areas

Damage can be detected, for example, in the form of cracks or deformations. By appropriate arrangement of the sensors 66, which can be connected to a corresponding evaluation and evaluation software, it can be seen how large the damage is and thus determine which parts must be removed or repaired. The damage report can appear as an indication on the on-board computer and / or be read out by means of a diagnostic device in the workshop.

Alternatively, the complete body damage detection can be designed as a central device in the workshop, by means of which, for example

Computed Tomography (CT) the entire body can be tested. In addition, smaller devices of this type are conceivable to a local test

make. In this case, in particular a small computer tomography device or a small ultrasound device is conceivable. As a base material for repair body components that consist of thermoplastic FRP and rejected in the production of semi-finished as a committee or damaged after installation in the motor vehicle, for example, in an accident, reuse be supplied. Here, the finished semifinished product is melted, wherein the plastic, preferably the polyamide

is dissolved out. The remaining fiber mats can be fed into the manufacturing process. Optionally, the dissolved out polyamide can also continue to be used and possibly processed introduced into the manufacturing process. Alternatively, the FRP can be shredded and supplied as a short-fiber FRP to the injection molding in the manufacturing process as reinforcement.

Claims

claims A body of a passenger car comprising a plurality of interconnected body components (10-14) at least partially provided with a plastic (24),  characterized in that  on the body a plurality of predetermined repair partitions (28-34) are provided, on which a correspondingly accidentally deformed body part (38 - 46) is separable from the rest of the body. 2. Body according to claim 1,  characterized in that  a thermoplastic material (24) is provided. 3. Body according to claim 1 or 2,  characterized in that  a repair body part (38 '- 46') is provided which has a respective overlap (48) with the rest of the body in the region of the separated repair partitions (28-34). 4. Body according to one of the preceding claims,  characterized in that  the body respective connection points (70) for cable sets (68) or the like. which are provided in the region of a repair separation point (28-34) and / or in the region of a connection component. 5. Body according to one of the preceding claims,  characterized in that  the body has a damage detection system. 6. A method for repairing a body of a passenger car, at  in which a plurality of body components (10-14) are connected to each other, which are at least partially provided with a plastic (24), characterized in that  a plurality of predetermined repair partitions (28-34) are provided on the body, on which a correspondingly accidentally deformed body part (38-46) is separable from the rest of the body. 7. The method according to claim 6,  characterized in that  a thermoplastic material (24) is provided. 8. The method according to claim 6 or 7,  characterized in that  a repair body part (38 '- 46') is provided which has a respective overlap (46) with the rest of the body in the region of the separated repair partitions (28-34). 9. The method according to any one of claims 6 to 8,  characterized in that  in the region of a deformation point (52) an additional body part (54) is added to the body. 10. The method according to any one of claims 6 to 9,  characterized in that  in the region of a deformation point (52) a hot forming, in particular a hot air forming, of the thermoplastic material (24) of the body is made.