Vehicle body part, in particular frame member.

The invention relates to a profile frame carrier for bodies of motor vehicles according to the preamble of claim 1 and to a body part according to the The preamble of claim 5 and a method according to the Preamble of claim 9.

The DE 195 46 352 A1 discloses Profile frame support for bodies of vehicles, one of the profile frame support circumscribed cavity with an aluminum foam material is filled and stiffened thereby. The aluminum foam material is either as a melt into the poured from the cavity profile frame support formed and foamed therein, or it will be outside the Profile frame beam first of foaming done and out of the finished foamed block Foam material a piece of suitable size for use cut into the panel frames support.

The foaming of a melt in the profile frame support However, this requires a suitable location for this part, the at least one side of the pouring closed have to be. A stuffing of a previously installed or preassembled in an assembly profile frame carrier is the current production of aluminum foam not possible.

The introduction of pre-built, a solid forming requires aluminum foam blocks in the frame profile carrier firstly a precisely fitting trimming these blocks, so that as a profile frame support only simple shapes, such as Square profiles, come in question, also is an additional Determination of foam blocks in the frame profile carrier required, the assembly costs and weight elevated.

In contrast, the invention is based on the problem Profile frame carrier or other, a cavity bounding Body parts form such that on the one hand a maximum flexibility in their production and, secondly, the fulfillment of a wide range of static and dynamic stresses, as in the body area occur, can be satisfied by the components.

The invention solves this problem with an object having the features of claim 1 and of claim 5, and by a method with the features of claim 9th

Through the arrangement of a structural component in the interior of a Profile frame member and the foaming of the interspace between the structural component and the profile frame support is a component formed which or as a frame Stiffener can use in the motor vehicle, for example, as the windshield frame or roll bar, However, in particular as a supporting part of the base structure, about as side skirts, which have been in Cabrioletbau arranged in the profile frame support tubes etc. indispensable to maintain the torsional stiffness were. Such internal structural members are so far preferably via web-like projections over the outer profile frame carrier supported.

The foaming of the space enables a planar Support of the inner structural component, so that over the entire course of the profile frame beam a uniform resistance occurring from the outside Deformations, particularly bending deformations as they occur in an accident, is achieved.

Through the use of a metallic cellular material to Filling up this gap is the same weight reduced compared to previous devices, the Wall thickness of the inner structural component, in particular Pipe can be lowered.

A body part, which with the addition of metallic Foam material, in particular aluminum foam material, Stuffed areas still contains cavities which remain free, offers the possibility to only those areas stiffen the body component, the special one subject to load. This can, for example, at a windshield frame the rising side his profile, which in the case of a rollover vertical have trap force components.

Also in the range of, for example, lateral cavities in doors such partially foamed body parts are used, wherein the foaming respectively adapted to the nature of the expected introduction of force is. Characterized in that according to the invention partial areas of the body parts can remain free in addition to foamed areas the space defined by the body part cavity, is the possibility of a considerable reduction of weight opened. Particular requirements for the position and arrangement of to be filled with metallic foam material Component are not provided.

With the method according to claim 9 it is possible that Foam material parts applicable to prepare that they verschiedenartigst in shaped body parts and profile frame beams be used and it fertiggeschäumt can. A limitation to the internal cross-section of a Profile frame beam is therefore no longer necessary. Nor is a vertical, closed on one side Installation position of auszuschäumenden profile support or body part necessary and instead, the introduction of Foam material parts in the ongoing production process made without a preliminary production of auszuschäumenden Components perform need to.

Further advantages and details will emerge from the Drawing and the following description of several Embodiments of the subject matter of the invention.

In the drawings:<dl tsize="7"><dt>Fig. 1</dt><dd>the broken side view of an automobile body with a profile frame carrier according to the invention in the sill area,</dd><dt>FIG. 2</dt><dd>a section along the line II-II of Fig. 1 </dd><dt>Fig. 3</dt><dd>a broken side view of an automobile body to a body part according to the invention as the windshield frame,</dd><dt>Fig. 4</dt><dd>a section along the line IV-IV from Fig. 3, and</dd><dt>Fig. 5</dt><dd>is a similar view to Fig. 4,</dd><dt>Fig. 6</dt><dd>is a fragmentary perspective view of a Convertibles with roll bar,</dd><dt>Fig. 7</dt><dd>a section along the line VII-VII of Fig. 6.</dd></dl>

Specifically, an inventive profile frame carrier 2, which is part of a motor vehicle body 1 and For example, a side sill (Fig. 1 and 2) or a windshield frame or roll bar (Fig. 6 and Fig. 7) is formed, an inner cavity 3 , in which a supporting tube 4 is arranged. This Tube 4 forms a structural component of the body and extends longitudinally of the outer profile frame carrier . 2

The cavity 3 between the inner tube 4 and the him surrounding profile frame beam 2 is in the final stage Parts of a foamed metal foam material 5 taken. This is about at the lateral Introduction of a force in the direction of arrow F, a large-scale support of the profile frame carrier 2 against reaches the inner structural member 4, so that the forces better than with a web-like Connection of the structural member 4 to the profile frame carrier 2 can be distributed and a buckling deformation of the Component only starts at considerably greater forces or the same force fails low. Both the rigidity the side sill or frame part other than his buckling stability are thus significantly increased, at the same time by the uniform foaming of the Cavity 3 the resistance of the component against an introduction of force from any direction increases.

The internal structural component 4 can variously be carried out, for example, as longitudinally folded Sheet, as a solid body or a hollow profile, in particular as a tube. Also, there might be cases in question come in that the inner structural member 4, a tension member forms, the different areas of a profile frame carrier 2, for example, if these kinks which holds together.

A disposed in the side skirts pipe 4 meets one hand the function to stiffen the side sill and to stabilize them against buckling deformations and Torsional strength the body 1 to increase overall, On the other hand, the inner hollow portion 5 of the tube 4 as a guide channel for cables, in particular as Cable channel, are used.

FIGS. 3 to 5 show the formation of a body part 2 ', as the windshield frame and therefore also is designed as a profile carrier and an internal Cavity 3 'is formed, the regions with Aussteifungsteilen 5 'of metallic foam material, in particular aluminum foam is filled.

For such a design of body parts 2 come ' not only profile frame carrier in question, but it can other body areas, especially cavities between an inner and an outer panel, such as in doors or in front portions of the hood, be filled with foam, thereby impacting on vulnerable Areas to effect reinforcement of the body 1, without having a hollow portion 3 completely foaming ' and characterized the weight of the body 1 considerably increase.

The foam-filled area 5 while 'takes only a part the cavity 3 'a, between foamed areas 5 'remain significant hollow spaces, for example, 20% of the cavity 3 ', so that a total of only Parts of a body part 2 ', for example a windscreen frame or the roll bar, with a metallic are filled foam material, which upon initiation of forces, such as occur in an accident, especially are claimed. The effect of the remaining hollow spaces opposite the foam all weight reduction. If the body part 2 'as a windshield frame or rollover bar is formed, are the parts that claimed in a rollover with vertical force introduction are, in particular the lateral uprights.

Such a body part 2 ', the regions stiffeners having metallic foam material, can additionally an internal structural component 4 have, so that a foamed in some areas similar cross-sectional view as in FIG. 2 or Fig. 7 results. Thus, on the one hand the high stability reserve from the inner structural member 4, for example be a pipe used, on the other hand, the large-scale support of a profile frame support 2 'on the pipe 4 to limit the areas to absorb the forces have. A Gesamtausschäumung the interspace between the tube 4 and the profile frame support 2 'is not necessary, so that weight can be saved can. Such regions, foaming with interior Structural part 4 has, for example, in Doors, where it represents a high weight gain would, a large gap between a Indoor and outdoor auszuschäumen.

For the formation of the components 2, 2-described 'are in the Cavity 3 of the profile frame carrier 2 or body part 2 'semi-finished products used of metallic foam material, the profile in the frame beam 2 or body part 2 ' be fertiggeschäumt by heating to its final form.

The final shape is in this case at least of the inner walls of the body part 2, 2 'is limited. The semi-finished product can be used as be formed primitive body or already an adjustment 'Have the shape of the cavity 3, 3, ie net shape to be preprocessed. The so introduced semifinished is within the body part 2, 2 'to its Fertiggeschäumt final shape by being heated there.

This heating can be done in various ways, for example, by induction, radiant heat, heat conduction or convection and electromagnetic through the use Waves, such as those used in laser technology be used. If in the profile frame beam 2 or other body part 2 'an internal structural component 4 arranged with a cavity therein containing 6 is, so also through this cavity 6 a heated Medium are conducted, whereby the gap between the structural part 4 and the outer member 2,2 'heated so that here a foaming of the introduced semifinished product is achieved.

Such inboard structural part 4 can on its the cavity 3 facing outside with a layer 7 be provided from aufzuschäumendem metallic material. This layer 7 need not be of the over the entire length Structural component 4 extend, but it is possible to Thus, only portions of the cavity 3 between the Profile frame beam 2 and the inner structural member 4 auszuschäumen between which cavities remain, as shown in claim eighth When heated, this Location 7 then provide the information contained in the foam material Foaming agents for foaming this situation, so that, as shown in the left part of FIG. 2, at End of the heating process in the cross section of the whole Cavity 3 the profile frame beam 2 and the inner Structural part 4 with expanded foam material 5 is filled, wherein the foam material 5 metallic Bonds to the body part 2.2 surrounding 'formed. Thus, a foaming is any Cavity cross section allows. One limitation to the Body part type is not used. A final contour prefabrication the semi-finished products to be introduced is not required.

Similarly, in addition to or instead, the inner wall the profile frame carrier 2 or other body part 2 'with a layer of foamed metallic be provided material, the foaming this material then passes through the inner Structural part 4 is limited.

Alternatively, it is also possible in the cavity 3 or a several individual bodies of metallic aufzuschäumendem Foam material to introduce, during the heating the cavity 3 at least in regions as far foaming, that the foaming of the inner wall of the body part 2 or 2 'and of the inner structural component 4 is limited.

Overall, this method offers the possibility of partial areas a body part 2.2 'stiffen such that a high resistance in these areas externally acting forces at the lowest possible weight the entire component is made possible. stiffness of the component can also by an internal structural component 4 increases, the metal through the Foam material surface to the outer body part is 2,2 'connected and therefore a wide range of Force introduction directions and introduction points a very high buckling and bending stiffness opposes.

In addition to the adaptability of the introduced stiffening to the requirements of the static and dynamic load of the body parts is through the The method according to the invention simultaneously mounting such simplified, that various portions of the vehicle body flexible in installation process with internal can be stiffened foam materials.