DE102019218126B4 - hybrid component - Google Patents

Abstract

Hybrid component with a rod-shaped body (2) made of fiber-reinforced plastic and extending in an axial direction (x), and a metal body (3) which encloses the rod-shaped body (2) in an axial end region (4), characterized in that a free space (8) is provided between the rod-shaped body (2) and the metal body (3) in the axial direction (x), in which a spacer (9) is arranged, by means of which the rod-shaped body (2) is axially supported on the metal body (3), and that when a maximum force (F) acting from the rod-shaped body (2) on the metal body (3) in the axial direction (x) is reached or exceeded, the spacer (9) is at least partially deformed or destroyed, so that the rod-shaped body (2) is pressed into the free space (8).

Description

The invention relates to a hybrid component with a rod-shaped body made of fiber-reinforced plastic extending in an axial direction and a metal body which encloses the rod-shaped body in an axial end region. Furthermore, the invention relates to a use of a spacer for a hybrid component.

From the DE 10 2013 217 769 A1 A hybrid component and its use are known, wherein the hybrid component has a rod-shaped body made of fiber-reinforced plastic extending in an axial direction and a metal body that encloses the rod-shaped body in an axial end region. The metal body has several free spaces or recesses.

From the DE 10 2013 201 183 A1 A connection arrangement for joining at least one non-joinable or only partially joinable component to a joining element is known, wherein in the region of a joining section of the joining element at least one force-fitting connection is formed between the joining element and the component due to residual joining stresses.

From the WO 99/03716 A1 A steering column arrangement is known, wherein an energy absorption element is arranged on a region of a first jacket tube part, which energy absorption element fixes a second jacket tube, wherein the first jacket tube protrudes from the second jacket tube.

Chassis for all types of motor vehicles are subject to a precisely defined chain of victims in the event of overloading due to driver error or in the event of a crash. Chassis links that fail first must also demonstrate a specific failure pattern. The requirement of "deformation before breakage" means that the component deforms from a predetermined overload in such a way that in the event of damage, e.g. when sliding sideways onto a curb, the link(s) deform in such a way that the driver, if he or she is still able to drive after the event, is advised to go to a workshop by a crooked steering wheel, for example. A crooked steering wheel is caused, for example, by at least one of the links deforming in the event of an impact so that it no longer has the original length.

In technical terms, a buckling load window is defined. This defines forces at which the control arm may be permanently deformed but not broken. Breakage is only permitted under even greater loads, which would then also result in total damage. The standard control arms used to date are therefore all made of materials with a breaking limit of > 10%. For example, a U-shaped sheet metal profile that forms a two-point control arm has a small notch in the profile, which is the nucleus for a defined bend when overloaded. Components made of glass fiber reinforced plastic (GRP) or carbon fiber reinforced plastic (CFRP) do not exhibit this deformation behavior. A stress-strain diagram of, for example, glass or carbon fibers shows a rather straight curve without a pronounced flow area until it breaks. Aluminum die-cast parts are also only partially suitable for replicating such deformations with repeatable accuracy. In addition, aluminum materials processed using the die-casting process rarely exhibit such high elongations at break. Nevertheless, the hybrid construction is desired because it makes it possible to save up to 50% of the weight at approximately the same cost.

Based on this, the invention is based on the object of developing a hybrid component of the type mentioned at the beginning in such a way that it changes its dimensions from a predetermined maximum load, but nevertheless remains functional.

This object is achieved by a hybrid component according to claim 1. Preferred developments of the hybrid component are given in the following description and in the subclaims.

A hybrid component with a rod-shaped body made of fiber-reinforced plastic extending in an axial direction and a metal body which encloses the rod-shaped body in an axial end region is further developed according to the invention in particular in that a free space is provided between the rod-shaped body and the metal body in the axial direction, in which a spacer is arranged, in particular at least partially, by means of which the rod-shaped body is axially supported on the metal body, and that when a maximum force acting from the rod-shaped body on the metal body in the axial direction is reached or exceeded, the spacer is at least partially deformed and/or destroyed, so that the rod-shaped body is engaged, in particular axially, into the free space, preferably until it stops on the metal body.

When the maximum force acting in the axial direction from the rod-shaped body on the metal body is reached or exceeded, the spacer is at least partially deformed and/or destroyed, so that the rod-shaped body, in particular axially, moves into the free space, preferably until it stops against the metal body. The hybrid component is thus shortened axially, but remains fundamentally functional.

Preferably, the rod-shaped body is assigned a longitudinal axis running in the axial direction. One or any direction running transversely to the axial direction and/or transversely to the longitudinal axis is referred to in particular as a radial direction.
The metal body is preferably connected to the rod-shaped body, particularly in the end region, preferably in a form-fitting and/or friction-fitting manner. The rod-shaped body is advantageously designed to be rotationally symmetrical, particularly with respect to the longitudinal axis. For example, the rod-shaped body is or will be manufactured using the pultrusion process.

The spacer is preferably designed to be rotationally symmetrical, particularly with respect to the longitudinal axis. The spacer preferably forms a dimensionally stable body. The spacer is made of metal or plastic, for example.

According to one embodiment, the fiber-reinforced plastic comprises fibers. In particular, the fibers of the fiber-reinforced plastic are continuous fibers. The fiber-reinforced plastic can thus also be referred to as continuous fiber-reinforced plastic, for example. For example, the fibers of the fiber-reinforced plastic are or comprise glass fibers and/or carbon fibers. The fibers preferably extend in the axial direction.

The fiber-reinforced plastic preferably comprises a matrix. In particular, the fibers are embedded in the matrix. The matrix preferably consists of plastic, in particular of a thermosetting plastic. For example, the matrix forms a thermosetting matrix. The matrix advantageously consists of resin or synthetic resin. For example, the matrix consists of epoxy resin. Alternatively, the matrix can consist of a thermoplastic plastic. In particular, the matrix forms a thermoplastic matrix.

According to a further development, the metal body is a cast part, preferably a die-cast part. In particular, the rod-shaped body is embedded with its end region in the metal body and/or in its material. The metal body is preferably made of aluminum.

According to one embodiment, the rod-shaped body is designed as a tube, in particular at least in the end region. Preferably, the tube and/or the rod-shaped body has a tube wall that delimits a tube interior. Preferably, the tube and/or the rod-shaped body has a front-side tube opening provided in the end region, in particular in the axial direction. The spacer is advantageously inserted through the tube opening into the tube interior. Preferably, the tube opening is closed, preferably tightly, by the spacer. The spacer forms in particular a plug. This is useful so that no molten metal penetrates into the tube interior when the metal body is manufactured using the die-casting process.

According to a further development, an annular sleeve embedded in the metal body and/or in its material sits on the rod-shaped body, in particular in the end region of the rod-shaped body, which preferably rests with its, in particular axial, ends on the rod-shaped body, preferably tightly, and/or has between its, in particular axial, ends at least one, in particular radial, projection protruding in the direction of the rod-shaped body, which is pressed into the rod-shaped body and/or into its material. As a result, the rod-shaped body is connected to the metal body in a form-fitting manner. This form-fitting connection is particularly suitable for the die-casting process. The form-fitting connection is preferably generated due to a casting pressure during die-casting. Alternatively, the form-fitting connection can be implemented as part of a preceding step using a suitable tool. The sleeve is also referred to, for example, as a claw sleeve. The at least one projection of the sleeve preferably comprises or forms one or at least one cutting edge. For example, the at least one projection is provided axially centrally on the sleeve. The sleeve is preferably designed to be rotationally symmetrical, in particular with respect to the longitudinal axis. The sleeve is made of metal or plastic, for example.

According to one embodiment, the metal body has at least one projection, in particular radial, which projects in the direction of the rod-shaped body and which engages in at least one, in particular radial, depression provided in the rod-shaped body, preferably in the end region of the rod-shaped body. As a result, the rod-shaped body is connected to the metal body in a form-fitting manner. For example, this projection and this depression are ring-shaped. Preferably, the spacer, preferably inside the pipe and/or in the pipe interior, has at least one, in particular radial, recess in its outer surface facing the pipe wall, into which the pipe wall is pressed and/or molded to form the at least one, in particular radial, depression. This form-fitting connection is particularly suitable for the die-casting process. Preferably, the form-fitting connection is generated due to a casting pressure during die-casting. Alternatively, the form-fitting connection can be realized in a preceding step using a suitable tool. The at least one recess is preferably provided between the, in particular axial, ends of the spacer. Preferably, the ends, in particular the axial ends, of the section of the spacer, advantageously radially, on the rod-shaped body and/or on the pipe wall. For example, the at least one recess is annular.

According to a further development, the spacer is supported axially on the metal body with a central region, preferably outside the rod-shaped body and/or the tube and/or the tube interior. For example, the spacer has a convex contact surface in the central region, which axially rests on a concave contact surface provided on the metal body. The convex contact surface is curved in particular in the axial direction towards the metal body.

The spacer preferably has a shear region, in particular one that protrudes radially from the or a central region of the spacer and/or surrounds the or a central region of the spacer, on which the tube and/or the rod-shaped body in particular is axially supported. The free space advantageously adjoins the shear region in the axial direction. The free space is preferably or forms an annular space. The shear region is preferably formed integrally with the central region and/or with the spacer. The shear region is advantageously formed in a ring shape. In particular, the spacer is arranged with its shear region in the free space. The shear region is advantageously provided outside the rod-shaped body and/or the tube and/or the tube interior. In particular, the rod-shaped body rests axially and/or at the front against the shear region. The shear region is also referred to as a flange, for example.
Preferably, when the maximum force acting from the rod-shaped body on the metal body in the axial direction is reached or exceeded, the shear region of the spacer and/or the central region is bendable and/or shearable or is bent and/or sheared off. In particular, the rod-shaped body is or is thereby engageable or engaged, preferably axially, into the free space, preferably until it stops against the metal body. Preferably, the spacer is or is thereby at least partially deformable and/or destroyable or deformed and/or destroyed by the shear region of the spacer and/or the central region being bendable and/or shearable or is bent and/or sheared off.

According to one embodiment, the hybrid component is or forms a chassis component which is installed in particular in the chassis of a vehicle, which is preferably a motor vehicle. For example, the hybrid component forms a chassis control arm, such as a wishbone or a trailing arm.

1. 1) Bei der Herstellung des Hybridbauteils unter Verwendung des Druckgussverfahrens zur Herstellung des Metallkörpers verdampft die Metallschmelze die Matrix des faserverstärkten Kunststoffs und legt dessen Fasern frei. An die Stellen fehlender Matrix fließt dann flüssiges Metall, vorzugsweise Aluminium und verbindet sich formschlüssig, oberflächlich mit den Fasern und/oder mit dem faserverstärkten Kunststoff. Je länger die Metallschmelze einwirkt, desto tiefer ist insbesondere die Eindringtiefe des Metalls.
2. 2) Durch einen Schrumpf, insbesondere bis zu 3%, beim Abkühlen der Metallschmelze erhöht sich die Vorspannung dieses Formschlusses.
3. 3) Der mit der Ausnehmung versehene, insbesondere taillierte, Abstandshalter (Stopfen) bringt durch die Verformung der Rohrwandung aufgrund des Gießdruckes weiteren Formschluss.
4. 4) Zusätzlich verhindert der Stopfen, dass sich das Rohr durch die Auszugs- oder Druckkraft im Durchmesser verkleinert, und sich so herausziehen könnte (insbesondere hervorgerufen durch den kleineren E-Modul der Epoxid-Matrix).
5. 5) Die Hülse oder Krallmanschette krallt sich durch den Gießdruck in die Oberfläche des Rohrs aus faserverstärktem Kunststoff und erhöht somit ebenfalls den Formschluss.

In order to ensure that the hybrid component changes in length when it is overloaded, a design was chosen in which the rod-shaped body and the metal component can slide into each other without causing any damage. The positive and/or frictional connection between the rod-shaped body made of fiber-reinforced plastic, which is designed in particular as a tube, and the metal body is made up of several components:

1. 1) When manufacturing the hybrid component using the die-casting process to produce the metal body, the molten metal evaporates the matrix of the fiber-reinforced plastic and exposes its fibers. Liquid metal, preferably aluminum, then flows to the areas where the matrix is missing and bonds positively and superficially with the fibers and/or with the fiber-reinforced plastic. The longer the molten metal is in effect, the deeper the penetration depth of the metal.
2. 2) Due to shrinkage, in particular up to 3%, when the molten metal cools, the prestress of this form fit increases.
3. 3) The spacer (plug) provided with the recess, in particular the waisted one, provides further form closure by deforming the pipe wall due to the casting pressure.
4. 4) In addition, the plug prevents the pipe from reducing in diameter due to the pull-out or compression force and thus being able to pull out (especially caused by the smaller E-modulus of the epoxy matrix).
5. 5) The sleeve or claw cuff claws into the surface of the fiber-reinforced plastic pipe due to the casting pressure and thus also increases the form fit.

These five components can be used to set the maximum holding force. If even higher forces are introduced (e.g. misuse), the component length should change due to deformation.

When all five parts of the form-locking forces are used up and the highest force occurs in the compression direction and/or in the axial direction, the pipe made of fiber-reinforced plastic slides inwards and/or axially into the metal body and/or into the free space. The shear area (flange) of the plug, which is the last component in the force flow chain and sets the maximum force to be tolerated, is sheared off and folds into the ring-shaped free space. The way is now clear for the pipe to move with maximum friction, which the five forces components can still be generated, axially into the metal body until it stops against the metal body. Since these high forces are always only temporary impulses, a few millimeters are enough for the impulse to subside. The component is still intact after this event and can continue to absorb tensile and compressive forces in the shortened state.

Preferably, the free space is visible from the outside. This means that after reaching or exceeding a maximum force acting in the axial direction from the rod-shaped body on the metal body, the rod-shaped body indented into the free space can be seen. In particular, the metal body has at least one material cutout in the area of the free space. Due to the material cutout, the free space is visible from the outside. The material cutout can be designed as a gap. The material cutout enables easy visual inspection, particularly when installed. This makes it easy and reliable to see whether or not an overload has occurred. If an overload is detected, the hybrid component can be replaced.

The invention further relates to the use of a spacer for a hybrid component with a rod-shaped body made of fiber-reinforced plastic extending in an axial direction and a metal body which encloses the rod-shaped body in an axial end region, wherein a free space is provided between the rod-shaped body and the metal body in the axial direction, in which the or a spacer is or will be arranged, in particular at least partially, by means of which the rod-shaped body is axially supported on the metal body, and wherein when a maximum force acting from the rod-shaped body on the metal body in the axial direction is reached or exceeded, the spacer is at least partially deformed and/or destroyed, so that the rod-shaped body engages, in particular axially, into the free space, preferably until it stops against the metal body.

When used, the hybrid component and/or the spacer can be further developed according to all embodiments explained in connection with the hybrid component.

• 1 eine Draufsicht auf ein Hybridbauteil gemäß einer ersten Ausführungsform,
• 2 einen Längsschnitt des Hybridbauteils gemäß der ersten Ausführungsform und
• 3 einen Längsschnitt eines Hybridbauteils gemäß einer zweiten Ausführungsform.

The invention is described below using preferred embodiments with reference to the drawing. In the drawing:

• 1 a plan view of a hybrid component according to a first embodiment,
• 2 a longitudinal section of the hybrid component according to the first embodiment and
• 3 a longitudinal section of a hybrid component according to a second embodiment.

Out of 1 1 shows a plan view of a hybrid component 1 according to a first embodiment, wherein the hybrid component has a rod-shaped body 2 made of fiber-reinforced plastic extending in an axial direction x and a metal body 3 which encloses the rod-shaped body 2 in an axial end region 4. The hybrid component 1 is assigned a longitudinal axis 12 extending in the axial direction x, with respect to which the rod-shaped body 2 is rotationally symmetrical. A longitudinal section of the hybrid component 1 along the longitudinal axis 12 is shown in 2 shown.

The rod-shaped body 2 is designed as a tube with a tube wall 6 delimiting a tube interior 5 and a front-side tube opening 7 provided in the end region 4. Between the rod-shaped body 2 and the metal body 3, a free space 8 is provided in the axial direction x, in which a spacer 9 is arranged, by means of which the rod-shaped body 2 is axially supported on the metal body 3. The spacer 9 is inserted through the tube opening 7 into the tube interior 5 and in particular forms a plug closing the tube opening 7.

The spacer 9 has at least one radial recess 15 inside the tube 2 in its outer surface facing the tube wall 6, into which the tube wall 6 is pressed or molded to form a radial depression 16. Furthermore, the metal body 3 has a radial projection 17 engaging in the depression 16. The rod-shaped body 2 is thus connected to the metal body 3 in a form-fitting manner.

The spacer 9 has a central region 10, with which the spacer 9 is axially supported on the metal body 3. In particular, the spacer 9 has a convex contact surface in the central region 10, which is curved in the axial direction towards the metal body and axially rests on a concave contact surface provided on the metal body 3. The spacer 9 also has an annular shear region 11 which projects radially from the central region and is formed integrally therewith, on which the pipe 2 is axially supported, the free space 8 being an annular space adjoining the shear region 11 in the axial direction x.

When a maximum force F acting from the rod-shaped body 2 on the metal body 3 in the axial direction x is reached or exceeded, the shear area 11 is bent or sheared off from the spacer 9, so that the rod-shaped Body 2 engages axially in the free space 8. In this embodiment, the metal body 3 has a material cutout in the area of the free space 8. Due to the material cutout, the free space 8 can be seen from the outside, whereby the material cutout is designed like a gap here. The material cutout in the area of the free space 8 enables a simple visual inspection.

The metal body 3 forms a housing and comprises a cylindrical recess 13 into which a rubber bearing 14 is inserted. The hybrid component 1 is designed here as a chassis control arm.

Out of 3 a longitudinal section of a hybrid component 1 according to a second embodiment is visible, wherein features identical or similar to the first embodiment are designated by the same reference numerals as in the first embodiment.

In contrast to the first embodiment, an annular sleeve 18 embedded in the metal body 3 sits on the rod-shaped body, which rests with its ends 19 on the rod-shaped body 2 and has between its ends 19 a radial projection 20 which protrudes in the direction of the rod-shaped body 2 and is designed as a cutting edge and is pressed into the rod-shaped body 2. The rod-shaped body 2 is thus positively connected to the metal body 3. The sleeve 18 is also referred to as a claw sleeve, for example. For a further description of the second embodiment, reference is made to the description of the first embodiment.

reference sign

1

hybrid component

2

tube / rod-shaped body

3

metal body

4

axial end region of the pipe

5

pipe interior

6

pipe wall

7

front pipe opening

8

open space

9

spacers

10

central area of the spacer

11

shear range of the spacer

12

longitudinal axis

13

recess

14

rubber bearings

15

radial recess in spacer

16

radial recess in pipe wall

17

radial projection of the metal body

18

sleeve

19

axial end of the sleeve

20

projection of the sleeve

Claims (14)

Hybrid component with a rod-shaped body (2) made of fiber-reinforced plastic and extending in an axial direction (x), and a metal body (3) which encloses the rod-shaped body (2) in an axial end region (4), characterized in that a free space (8) is provided between the rod-shaped body (2) and the metal body (3) in the axial direction (x), in which a spacer (9) is arranged, by means of which the rod-shaped body (2) is axially supported on the metal body (3), and that when a maximum force (F) acting from the rod-shaped body (2) on the metal body (3) in the axial direction (x) is reached or exceeded, the spacer (9) is at least partially deformed or destroyed, so that the rod-shaped body (2) is pressed into the free space (8). Hybrid component according to claim 1 , characterized in that an annular sleeve (18) embedded in the metal body (3) sits on the rod-shaped body (2), which rests with its ends (19) on the rod-shaped body (2) and has between its ends (19) at least one projection (20) projecting in the direction of the rod-shaped body (2) and is pressed into the rod-shaped body (2). Hybrid component according to claim 1 or 2 , characterized in that the metal body (3) has at least one projection (17) projecting in the direction of the rod-shaped body (2) which engages in at least one recess (16) provided in the rod-shaped body (2). Hybrid component according to one of the preceding claims, characterized in that the rod-shaped body (2) is designed as a tube with a tube wall (6) delimiting a tube interior (5) and a front-side tube opening (7) provided in the end region (4), through which the spacer (9) is inserted into the tube interior (5). Hybrid component according to claim 4 , characterized in that the spacer (9) is supported axially on the metal body (3) with a central region (10) and has a shear region (11) projecting radially from the central region (10) on which the rod-shaped body (2) is axially supported, wherein the free space (8) is an annular space adjoining the shear region (11) in the axial direction (x). Hybrid component according to claim 5 , characterized in that when the maximum force (F) acting from the rod-shaped body (2) on the metal body (3) in the axial direction (x) is reached or exceeded, the shear region (11) is bent or sheared off from the spacer (9). Hybrid component according to one of the preceding claims, characterized in that the fiber-reinforced plastic of the rod-shaped body (2) comprises continuous fibers embedded in a matrix. Hybrid component according to one of the preceding claims, characterized in that the metal body (3) is a cast part in which the rod-shaped body (2) is embedded with its end region (4). Hybrid component according to one of the preceding claims, characterized in that the metal body (3) forms a housing in which a joint or rubber bearing (14) is installed. Hybrid component according to one of the preceding claims, characterized in that the free space (8) is visible from the outside, whereby after reaching or exceeding a maximum force (F) acting from the rod-shaped body (2) on the metal body (3) in the axial direction (x), the rod-shaped body (2) inserted into the free space (8) can be seen. Use of a spacer (9) for a hybrid component (1) with a rod-shaped body (2) made of fiber-reinforced plastic extending in an axial direction (x) and with a metal body (3) which encloses the rod-shaped body (2) in an axial end region, wherein a free space (8) is provided between the rod-shaped body (2) and the metal body (3) in the axial direction, in which the spacer (9) is arranged, by means of which the rod-shaped body (2) is axially supported on the metal body (3), and wherein when a maximum force acting from the rod-shaped body (2) on the metal body (3) in the axial direction is reached or exceeded, the spacer (9) is at least partially deformed or destroyed, so that the rod-shaped body (2) engages in the free space (8). Use after claim 11 , characterized in that the rod-shaped body (2) is designed as a tube with a tube wall (6) delimiting a tube interior (5) and a front-side tube opening (7) provided in the end region (4), through which the spacer (9) is inserted into the tube interior (5). Use after claim 12 , characterized in that the spacer (9) is supported axially on the metal body (3) with a central region (10) and has a shear region (11) projecting radially from the central region (10), on which the rod-shaped body (2) is axially supported, wherein the free space (8) is an annular space adjoining the shear region (11) in the axial direction (x). Use after claim 13 , characterized in that when the maximum force (F) acting from the rod-shaped body (2) on the metal body (3) in the axial direction (x) is reached or exceeded, the shear region (11) is bent or sheared off from the spacer (9).

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