U.S. patent application number 10/575910 was filed with the patent office on 2007-03-15 for component for a motor vehicle.
This patent application is currently assigned to BEHR GmbH & CO. KG. Invention is credited to Thomas Feith, Jochen Schmitz, Volker Unholz, Walter Wolf.
Application Number | 20070056748 10/575910 |
Document ID | / |
Family ID | 34442200 |
Filed Date | 2007-03-15 |
United States Patent
Application |
20070056748 |
Kind Code |
A1 |
Feith; Thomas ; et
al. |
March 15, 2007 |
Component for a motor vehicle
Abstract
Disclosed is a component (1), particularly a crossbeam that is
to be disposed between the A-shaped columns of a motor vehicle.
Said component (1) comprises an essentially tubular or other
elongate metallic basic member (1) to which a plastic (7) channel
(2), especially a ventilation channel, is connected at least in
part within the profile of said basic member (1), and a joining
part (4) that is mechanically connected to the basic member (1) or
a part rigidly connected thereto and is used for fixing another
component. Said joining part (4) forms a material bond with the
basic member (1) or a part rigidly connected thereto at a joining
point (5), thus creating an intermediate area (12) so as to reduce
heat transfer between the joining part (4) and the plastic (7) of
the channel (2) and/or drain away a gas produced during the joining
process.
Inventors: |
Feith; Thomas;
(Korntal-Muchingen, DE) ; Schmitz; Jochen;
(Leonberg, DE) ; Unholz; Volker; (Stuttgart,
DE) ; Wolf; Walter; (Oppenweiler-Zell, DE) |
Correspondence
Address: |
FOLEY AND LARDNER LLP;SUITE 500
3000 K STREET NW
WASHINGTON
DC
20007
US
|
Assignee: |
BEHR GmbH & CO. KG
Mauserstrasse 3
Stuttgart
DE
D-70469
|
Family ID: |
34442200 |
Appl. No.: |
10/575910 |
Filed: |
October 15, 2004 |
PCT Filed: |
October 15, 2004 |
PCT NO: |
PCT/EP04/11591 |
371 Date: |
August 16, 2006 |
Current U.S.
Class: |
166/387 |
Current CPC
Class: |
B62D 25/142 20130101;
B62D 29/004 20130101; B62D 29/001 20130101; B62D 29/005
20130101 |
Class at
Publication: |
166/387 |
International
Class: |
E21B 33/12 20060101
E21B033/12 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 17, 2003 |
DE |
103 49 138.4 |
Claims
1. A component, in particular crossmember, for arranging between
A-pillars of a motor vehicle, with a metallic basic body which has
essentially a tubular form or another elongated form and to which a
duct, in particular ventilation duct, of plastic is connected at
least partially within the profile of the basic body, and with a
joining part which is connected mechanically to the basic body or
to a part connected rigidly thereto and is used for fastening a
further component, characterized in that the joining part is
connected at a joining point with a cohesive material joint to the
basic body or to a part connected rigidly thereto with an
intermediate region being formed in order to reduce the heat
transfer between the joining part and the plastic of the duct
and/or to conduct away a gas produced during the joining.
2. The component as claimed in claim 1, wherein the duct is
connected to the basic body by means of plastic injection molding
in a strength-transmitting manner.
3. The component as claimed in claim 1, wherein the joining point
is arranged directly on the basic body.
4. The component as claimed in claim 3, wherein in the region
provided for the fastening of the joining part, the basic body has
an embossed structure which is designed in such a manner that the
wall of the duct, which is otherwise formed from plastic, is formed
in the intermediate region adjoining the joining point from the
material of the basic body.
5. The component as claimed in claim 4, wherein the sum of the
embossed depth (p) of the embossed structure and of the wall
thickness (a) of the basic body corresponds at least approximately
to the wall thickness (d) of the duct.
6. The component as claimed in claim 3, wherein the joining point
is formed on a bent-outward part of the basic body, which
bent-outward part points away from the duct.
7. The component as claimed in claim 1 wherein the joining point is
arranged on an inset part connected rigidly to the basic body.
8. The component as claimed in claim 1, wherein on its outer side
facing the basic body the duct has a surface structure forming the
intermediate region.
9. The component as claimed in claim 1, wherein the jointing part
is connected to the basic body at the joining point by means of a
low-heat joining method.
Description
[0001] The invention relates to a component, in particular a
crossmember, for arranging between the A-pillars of a motor
vehicle, with a basic body made from metal which is of essentially
tubular design or is designed in the form of an elongated shell,
i.e. an open profile, and with a duct, in particular ventilation
duct, of plastic which is at least partially surrounded by the
profile of the basic body and is connected mechanically thereto. A
component of this type is known from DE 100 64 522 A1, for
example.
[0002] In a motor vehicle, a saving on weight and/or construction
space is possible by a crossmember connecting the A-pillars being
used at the same time for guiding air. By lining the crossmember
with plastic, both the stability of the crossmember can be
increased and the probability of condensation from moisture
contained in the air-conditioned air to be supplied to the vehicle
interior can be reduced. Connecting points for further components,
for example steering column or airbag, are typically arranged on
the crossmember. Connecting points of this type are generally
realized by joining parts welded to the crossmember. However,
because of the thin-walled design of the crossmember that has only
been made possible by the stabilizing plastic lining, the
production of welding connections on the crossmember is
problematic. The application of heat to the outer side of the
crossmember very rapidly brings about an increase in temperature on
its inner side, which can damage the plastic forming a ventilation
duct. Furthermore, it is also possible for gas to be produced by
the heated plastic or by evaporation of surface coatings, for
example zinc layers. This gas may penetrate the molten metal of the
weld seam and form pores or blow the liquid welding material out of
the weld seam.
[0003] The invention is based on the object of indicating a
component, in particular a crossmember of a motor vehicle, which
comprises an elongated basic body made from metal and a duct, in
particular ventilation duct, of plastic connected mechanically
thereto, and is distinguished by particularly economical production
and further processing possibilities.
[0004] This object is achieved according to the invention by a
component with the features of claim 1. In this case, a duct formed
at least primarily from plastic is connected mechanically to a
metallic basic body essentially having the form of a tube or an
open profile, in particular crossmember between the A-pillars of a
motor vehicle. The basic body or a part connected rigidly thereto
has at least one joining point for connection with a cohesive
material joint to a joining part provided for the fastening of a
further component. At least in the region of the joining point, the
basic body, the part connected rigidly thereto and/or the duct has
a form making it possible for an intermediate region to be provided
between the joining point and the plastic forming a wall of the
duct. The intermediate region reduces the heat transfer between the
joining point and the plastic of the duct. The duct wall, which is
at least predominantly formed from plastic, is therefore not
disadvantageously affected by the application of heat at the
joining point. In addition, if corresponding temperatures of the
plastic are reached, the intermediate region preferably acts as a
degassing opening or degassing gap and therefore permits the
removal of gas formed from the plastic of the duct or from material
evaporating from surface layers during the joining, in particular
welding.
[0005] In a particularly economical manner, the duct is preferably
connected to the profile of the basic body by means of the
injection molding method in a force-transmitting manner. In this
case, the plastic of the duct penetrates openings in the basic body
during the injection molding method, so that the hybrid component
produced in this manner has connecting elements, which are formed
by the plastic in the manner of rivet connections. Additional
connecting elements between the basic body, in particular
crossmember, and the duct, in particular ventilation duct, are not
required in this production method. The component is preferably
designed geometrically in such a manner that, in order to produce
the duct in the injection molding method, just a simply constructed
injection mold, ideally in the form of what is referred to as an
open-closed mold without or with a small number of additional
slides, is required. Alternatively, however, the duct may also be
premanufactured and connected mechanically to the component by
adhesive connections, clip connections, collar-type joining and/or
in another manner.
[0006] Irrespective of the production method, in particular IMA
method (In-Mold Assembly) or PMA method (Post-Mold Assembly), the
duct is already arranged in or on the component before the joining
part, which serves, for example, for the fastening of an airbag or
for the mounting of the steering column, is connected thereto with
a cohesive material joint. By not connecting the joining part to
the basic body until after the duct is introduced into the basic
body or the duct is connected to the basic body, tolerance problems
which are to be anticipated in other situations are avoided.
Furthermore, this makes it possible in particular to produce
economical manufacturing by injection molding with production at
the same time of a strength-transmitting connection to the basic
body without using complicated slides or sealing devices at the
joining points.
[0007] According to a preferred refinement, the joining point is
situated directly on the basic body. In this connection, if it is
possible when the strength requirements are taken into
consideration, the insertion of reinforcing additional parts, such
as plates, into the profile of the basic body in the region of the
joining point is omitted. In the region provided for the fastening
of the joining part with a cohesive material joint, the basic body
preferably has an embossed structure, in particular a knob or rib
structure, which ensures that the joining point is spaced apart
from the plastic of the duct. It is therefore possible solely by
the form of the basic body to produce a spacing between the joining
part and parts of the component which are formed from plastic, said
spacing reducing the heat transfer between the joining point and
the plastic. The embossed structure is preferably designed in such
a manner that the wall of the duct, which is otherwise formed from
plastic, is formed in the intermediate region adjoining the joining
point exclusively from the material of the basic body. This can be
realized in terms of manufacturing in a simple manner by the knobs,
ribs or other embossed structures of the basic body being impressed
from the outer side thereof to such a depth that the plastic
applied to the inner side of the profile of the basic body to
produce the duct only forms a wall of the duct in surface regions
of the basic body outside the knobs, ribs or similar
depressions--as viewed from the outer side of the profile. By
contrast, in the region of the depressions mentioned, the wall of
the duct is formed by the material of the basic body. An overall
smooth, inner surface of the duct can be produced by the sum of the
embossed depth of the embossed structure of the basic body and of
the wall thickness of the basic body corresponding at least
approximately to the wall thickness of the duct in the region
outside the depressions. Overall, the inner surface of the duct,
including the depressions which do not have any plastic, is formed
for the most part from plastic, so that the condensation problems
typically arising in the case of ducts made from metal are avoided.
Furthermore, the embossed structure of the basic body at the same
time increases the mechanical stability of the component in a
particularly advantageous manner.
[0008] Despite the good heat conduction of the metallic basic body,
regions of the duct wall that are lined with plastic or are formed
entirely from plastic are spaced apart sufficiently far from the
joining point in order to permit welding at this point. The at
least limited thermal decoupling of the joining point from the duct
makes it possible for the joining point to be configured with large
dimensions with a correspondingly extensive introduction of force
from the joining part into the basic body. This is all the more
advantageous the thinner-walled the design of the basic body is.
The component is therefore of particularly weight-saving design
with a great degree of design freedom with regard to the
arrangement and form of the joining parts. A particularly uniform,
extensive introduction of force is preferably provided by the fact
that the joining part is connected to the basic body with a
cohesive material joint, in particular is welded, not only at
individual points or lines, in particular outer contours, but also
has joining points which extend over relatively large areas, for
example in the form of weld seams in the manner of a honeycomb
pattern or cross-hatching.
[0009] In the region adjacent to the joining point, the basic body
preferably has one or more apertures, preferably holes or punched
portions, as degassing openings, which form the intermediate region
or part of the intermediate region. Degassing openings of this
type, for example produced by a laser beam before the welding on of
the joining part, are preferably combined with embossed portions of
the basic body and/or of the joining part fastened thereon, which
form ducts or other cavities through which gases arising during the
joining method can escape. In addition, the joining part preferably
also has openings and/or contours interacting with the degassing
openings of the basic body.
[0010] According to a preferred development, the joining point is
formed on at least one bent-outward part of the basic body, which
bent-outward part is spaced apart at this point from the duct, in
particular ventilation duct, and is bent outward, i.e. points away
from the duct. Both a particularly large spacing of the joining
point from the plastic of the duct and a particularly extensive
connection of the basic body to the joining part can therefore be
produced. A particularly economical production of the component is
also made possible in this refinement by the fact that the joining
point is arranged directly on the basic body, without further
auxiliary elements.
[0011] In a departure from the previously described, single-part
design of the basic body with the joining point arranged on the
surface of the duct and/or on the bent-outward part, a separate
part, in particular an "insert part", can also be connected, for
example welded, to the basic body, which part has the joining point
for the connection with a cohesive material joint to a further
component. In this case, the insert part preferably has a subregion
arranged within the profile of the basic body, i.e. on that side of
the basic body which faces the duct, and a subregion protruding out
of the duct. The inner subregion is preferably injected into the
duct at the same time as the duct is produced in the injection
molding method, with, in comparison to an injection mold which is
provided for producing a component without additional insert parts
or adaptors, the injection mold not being of more complicated
design or only being of insignificantly more complicated design, in
particular not having an additional slide. In a particularly
advantageous manner, an additional reinforcing of the component is
provided by the insert part. The wall thickness of the insert part
is preferably dimensioned in such a manner that the wall of the
duct is free from plastic in regions in which the insert part bears
against the basic body, with an overall at least approximately
smooth surface being formed. The insert part therefore forms at
least part of the intermediate region between the joining point, in
particular welding root, and the plastic wall of the duct. In this
case, the joining point is situated on that part of the insert part
which is arranged outside the basic body and/or within a surface
region of the basic body on which the inner subregion of the insert
part rests. In particular in the design with separate insert parts,
the component has the advantage that the manufacturing of various
variants is possible without or only with slight modification of
the basic body serving as the base part.
[0012] According to all of the above-explained designs of the
component, the intermediate region is primarily produced by the
design of a part manufactured from metal in order to protect the
plastic of the duct. In a departure from this, or in a combination
with these refinements, according to further refinements the at
least one intermediate region, which preferably forms both an
insulation space and a degassing gap, is produced by the surface
structure of the plastic of the duct. This is advantageous in
particular in cases in which a premanufactured ventilation duct is
connected to the basic body by adhesive bonding and/or mechanical
connecting devices. Intermediate regions are formed, for example,
by ribs or other elevations of the duct, which is entirely
manufactured from plastic, that bear against a essentially smooth
inner surface of the basic body.
[0013] Irrespective of the geometrical design of the basic body and
of the duct, the joining part is preferably connected to the basic
body by means of a low-heat joining process, for example laser
welding or electron beam welding. In this manner, even in the case
of a thin-walled basic body, at most a small distortion occurs
because of the joining.
[0014] The advantage of the invention resides in particular in the
fact that, in spite of a thin-walled design of the basic body, an
economical, reliable, mechanically highly loadable connection of
the crossmember to joining parts to be fastened at the joining
points is made possible by the strength-transmitting connection of
a metallic basic body of a crossmember of a motor vehicle to a
ventilation duct having a wall at least predominantly of plastic,
and the formation of intermediate regions, which serve to reduce
the heat transfer, between joining points arranged directly on the
basic body and the plastic of the ventilation duct which is
introduced into the basic body in the injection molding method.
[0015] A number of exemplary embodiments of the invention are
explained in more detail below with reference to a drawing, in
which:
[0016] FIG. 1 shows the profile of a crossmember according to the
prior art,
[0017] FIG. 2 shows the crossmember according to FIG. 1 with
injected ventilation duct according to the prior art,
[0018] FIGS. 3a, 3b show a component with a crossmember as basic
body with injected ventilation duct and joining part, connected
with a cohesive material joint, according to the invention,
[0019] FIGS. 4 to 7 show further exemplary embodiments of
components in each case in a view analogous to FIG. 3,
[0020] FIGS. 8a, 8b show an exemplary embodiment of a component
with a joining point, which is provided for connection with a
cohesive material joint to a joining part, on a bent-outward part
of a basic body,
[0021] FIGS. 9, 10 show further exemplary embodiments of components
in each case in a view analogous to FIG. 8a,
[0022] FIG. 11 shows an exemplary embodiment of a component with
isolating intermediate regions formed between the outer surface of
a ventilation duct and a basic body,
[0023] FIG. 12 shows an exemplary embodiment of a component with a
plurality of ventilation ducts,
[0024] FIGS. 13a, 13b show, in a perspective view and in a partial
cross section, a further exemplary embodiment of a component with a
joining part welded onto a basic body,
[0025] FIG. 14 shows, in detail in a partially cutaway, perspective
view, the fastening of a joining part to a component,
[0026] FIGS. 15a, 15b show, in detail in a perspective view and in
cross section, a further exemplary embodiment of a fastening of a
joining part to a component,
[0027] FIGS. 16a to d each show, in a diagrammatic view, the
structure of a joining part in plan view or in cross section,
[0028] FIG. 17 shows, in cross section, a further exemplary
embodiment of a metal/plastic composite component, produced in the
PMA method,
[0029] FIGS. 18a, 18b each show, in a perspective illustration, an
exemplary embodiment of a basic body with a joining part fastened
thereto,
[0030] FIGS. 19a, 19b respectively show, in a diagrammatic view, a
detail of the basic body and of the joining part according to FIG.
18b, and
[0031] FIGS. 20a, 20b show, in a perspective view and in cross
section, a crossmember with injected ventilation duct and
additional insert parts.
[0032] Parts which correspond to one another or act in an identical
manner are provided with the same designations in all of the
figures.
[0033] FIG. 1 shows, in cross section, a crossmember 1 which is
made from metal, is basically known with regard to its function and
forms the basic body of a component according to the invention that
is explained in more detail below. The crossmember 1, also referred
to as instrument carrier, is arranged between the A-pillars of a
motor vehicle as a supporting part of the body structure and is
used, inter alia, for the mechanical joining of further components,
for example of an airbag housing.
[0034] The arrangement according to FIG. 2, which shows the
crossmember 1 with the duct or ventilation duct 2 of plastic with a
circular cross section that is integrally formed in the injection
molding method is likewise basically known, for example from DE 100
64 522 A1. The ventilation duct 2 which at least slightly increases
the stability of the crossmember 1 extends along the crossmember 1
and is therefore used to distribute additional air in the
transverse direction of the vehicle.
[0035] FIGS. 3a and 3b show, in an arrangement analogous to FIGS. 1
and 2, the basic construction of a component 3 according to the
invention. In addition to the basic body or crossmember 1 and to
the ventilation duct 2 connected thereto by means of the plastic
injection molding method, a joining part 4 merely illustrated in
symbolized form is provided here. The joining part 4, like the
basic body 1, is manufactured from metal and is fastened thereto by
a weld seam 5, referred to in general as joining point. In contrast
to the exemplary embodiment according to FIG. 2, the basic body 1
in the exemplary embodiment according to FIG. 3 has an embossed
structure 6 in the form of a knob structure which imparts a
substantially improved mechanical stability to it and penetrates
the plastic 7 of the ventilation duct 2. In this case, the
individual knobs 8 of the embossed structure 6 protrude in the
direction of the interior of the duct 2.
[0036] While the outer side 9 of the ventilation duct 2 is formed
exclusively from the material of the basic body 1 in its top region
in the illustration, i.e. above two webs 10 which adjoin the
circular ventilation duct 2 in the radial direction as parts of the
basic body 1, the inner side 11 has regions made from metal, namely
the knobs 8, and otherwise a surface made from plastic 7. The wall
thickness of the ventilation duct 2, which wall thickness is
approximately constant over the entire circumference, is denoted by
d, the wall thickness of the basic body 1 by a, and the embossed
depth of the embossed structure 6 by p. As is apparent in
particular from the view of the detail according to FIG. 3a, the
sum of the embossed depth p and of the wall thickness a of the
basic body 1 corresponds to the wall thickness d of the ventilation
duct 2. Those inner surface regions of the ventilation duct 2 which
are formed from plastic and which extend overall over most of the
inner surface of the ventilation duct 2 therefore adjoin the knobs
8 made from metal with a smooth surface being formed. The weld seam
5 is situated in the region of a knob 8, as a result of which an
intermediate region 12 separating the joining point 5 from the
plastic 7 of the ventilation duct 2 is formed. This intermediate
region 12 permits the joining part 4 to be welded onto the basic
body 1 after the ventilation duct 2 is formed in the basic body 1,
without risk of the plastic 7 being damaged. Conversely, the
quality of the weld seam 5 is not impaired by the plastic 7
either.
[0037] FIGS. 4 to 7 each show, in a specific refinement of the
basic example according to FIGS. 3a and 3b, an exemplary embodiment
of a component 3 with a different design of at least one joining
part 4. In each case, joining points 5 are situated exclusively in
regions of the basic body 1 that have not been encapsulated with
plastic 7 during the injection molding method, so that an
intermediate region 12 of at least small dimensions is formed. The
joining parts 4, which are formed from punched and/or bent plates
and are essentially aligned either longitudinally or transversely
to the extent of the basic body 1, are welded to the basic body 1
in the region of one or more knobs 8. Holes 13 are provided for the
mechanical connection of the joining parts 4 to further components
(not illustrated).
[0038] The exemplary embodiments according to FIGS. 8a and 8b to 10
show an alternative arrangement of the joining points 5. In this
case, the basic body 1 has in each case at least one bent-outward
part 14 which is either bent as a limb 15 out of the basic body 1
or is designed, preferably likewise integrally with the basic body
1, as an oblong or round eyelet 16. As is revealed in FIG. 10, a
joining part 4 can be fastened to the inside or outside of an
eyelet 11. The bent-outward parts 14 are formed before the
ventilation duct 2 is introduced into the basic body 1. In
particular the view of a detail according to FIG. 8b reveals that
the plastic 7 also surrounds the basic body 1 on the outer side 9
in the region which is adjacent to an aperture 17 produced by the
formation of the bent-outward part 14. This improves the
force-transmitting connection between the ventilation duct 2 and
the basic body 1.
[0039] In the exemplary embodiment according to FIG. 11, the basic
body 1 has a profile which corresponds to the crossmember 1
according to the abovementioned exemplary embodiment. However, in
contrast thereto, the ventilation duct 2 is not injected into the
basic body 1 but rather is premanufactured and is subsequently
connected to the basic body 1 by adhesive bonding, clipping or
collar-type joining. In its region facing the basic body 1, the
ventilation duct 2 has, on its outer side, an uneven surface
structure with ribs 18 which form a plurality of intermediate
regions 12 as insulation spaces between the ventilation duct 2 and
the basic body 1. Joining parts 4 are fastened to the basic body 1
exclusively in the region of these insulation spaces 12. If, during
the joining of the joining part 4, heating occurs at the joining
point 5 leading to the plastic 7 producing gas, the gas escapes
through the intermediate regions 12, which are designed as ducts.
In a manner not illustrated specifically, if required openings are
provided in the basic body 1 for further conducting away of the
gas.
[0040] FIG. 12 shows an exemplary embodiment of a component 3
having an essentially rectangular cross section within which two
rectangular ventilation ducts 2 run. Both ventilation ducts 2 are
spaced apart from side walls 19 of the basic body 1 and adjoin a
base surface 20 of the basic body 1. Joining points 5 are provided
exclusively in regions of the basic body 1 in which no wall of a
ventilation duct 2 adjoins the inner side of the plate forming the
basic body 1. The welding of a joining part 4 (not illustrated
here) onto the basic body 1 therefore causes the plastic 7 at most
to be melted locally in regions outside the ventilation ducts 2. To
avoid impairing the weld seams 5, in the adjacent regions the
plastic 7 advantageously has apertures (not illustrated), for
example punched portions. Punched portions of this type, through
which the gas formed from the plastic 7 can escape, can also be
provided in a corresponding manner in the other exemplary
embodiments.
[0041] FIGS. 13a and 13b show, in a perspective overall view and in
a diagrammatic, cutaway view of a detail, the fastening of a
joining part 4 with an embossed structure on the smooth surface of
a basic body 1. The basic body 1, including the ventilation duct 2
having a circular cross section, is produced as a hybrid component
in the injection molding method. The joining part 4 is essentially
in the form of a bent sheet-metal strip with a first supporting
limb 21 resting on the basic body 1 and a second fastening limb 22
provided for the fastening of a component (not illustrated), for
example an airbag. The supporting limb 21 has a central hole 23,
the fastening limb 22 has two holes 24. The supporting limb 21
which is curved corresponding to the curvature of the crossmember 1
has an embossed structure 25 which, in plan view, has a crosswise
pattern and, in cross section, has a wavy form. Those regions of
the embossed structure 25 which rest on the crossmember 1 form the
joining point 5. The intermediate region 12 is formed between those
regions of the embossed structure 25 which are spaced apart from
the basic body 1 and the surface of the basic body 1. In the region
lying opposite the supporting limb 21, the basic body 1 has a
number of openings 26 which are used to conduct away gas which has
separated off from the plastic 7 or a coating, for example zinc,
during the welding as the joining method. The gas which arises is
conducted further away from the joining point 5 both at the side
edges of the supporting limb 21 and also through the hole 23. The
overall approximately sheet-like connection of the supporting limb
21 to the basic body 1 permits, together with the duct 2 which is
connected extensively and non-positively to the basic body 1, a
lightweight and nevertheless stable design of the component 3.
[0042] FIG. 14 illustrates a detail of a further exemplary
embodiment of a fastening of a joining part 4 to a basic body 1. In
this case, the joining part 4 is only welded to the basic body 1 in
the edge regions, with a flat intermediate region 12 which is
connected to the outside via a hole 23 being formed in the central
region of the supporting limb 21. The openings 26 in the basic body
1 are produced by laser machining, for example before the joining
part 4 is welded on. In the illustrated manner or in a similar
manner, a multiplicity of joining parts 4 can be connected in a
flexible manner in terms of manufacturing to the basic body 1 at
any desired points.
[0043] In a departure from the exemplary embodiments according to
FIGS. 13a, 13b and 14, FIGS. 15a and 15b show an exemplary
embodiment in which the surface of the basic body 1 is corrugated
while the supporting limb 21 welded thereto is flat. In this case,
the openings 26 in the basic body 1 are designed as slots.
[0044] FIGS. 16a to 16c show diagrammatically different designs of
the supporting limb 21, namely a pattern of holes (FIG. 16a), a
honeycomb pattern (FIG. 16b) and a combined honeycomb/knob pattern
(FIG. 16c). The diagrammatic cross section according to FIG. 16d
relates to each of the exemplary embodiments according to FIGS. 16a
to 16c. In principle, very different surface structures of the
supporting limb 21 with depressions and/or elevations can be used.
In the region of the joining points 5, the basic body 1 preferably
has a surface structure which is matched to them. In this context,
the structures illustrated in FIGS. 16a to 16c also relate to the
surface of the basic body 1.
[0045] FIG. 17 shows, in a diagrammatic cross section, a further
exemplary embodiment of a component 3 with a metallic basic body 1
having an essentially trapezoidal cross section, and a ventilation
duct 2 connected mechanically thereto. Joining points 5 for the
welding on of joining parts 4 are provided exclusively at those
points of the basic body 1 at which no wall of the ventilation duct
2 is situated on the inner side of the profile of the basic body 1.
The component 3 is produced, for example, in the PMA method.
[0046] The exemplary embodiments according to FIGS. 18a and 18b
show basic possibilities of fastening a voluminous joining part 4
to the basic body 1. In this case, the joining part 4 has a
fastening arm 27 which rests on the basic body 1 and is to be
welded thereto. Before the welding takes place, the joining part 4
is already held in a form-fitting manner on the basic body 1 by
means of the fastening arm 27.
[0047] FIGS. 19a and 19b show, in schematized form, surface
structures of the basic body 1 (FIG. 19a) and of the joining part 4
(FIG. 19b) in the region of the fastening arm 27 according to FIG.
18b. In this case, openings 26 are provided in the basic body 1 and
notches 28 are provided in the fastening arm 27 to permit gas to be
conducted away from the plastic 7.
[0048] FIGS. 20a and 20b show, in a schematized cross section and
in a perspective view, an exemplary embodiment of a component 3
which, in addition to the basic body 1 and ventilation duct 2, has
a ribbed structure 29 of plastic 7 which is produced together with
the ventilation duct 2 in the injection molding method. In this
case, the bent-outward parts 14 are not formed from the basic body
1 but rather are designed as insert parts 30 which in each case
have an inner section 31 which bears against the inside of the
basic body 1, is curved in this exemplary embodiment and the wall
thickness of which corresponds at least approximately to the wall
thickness d of the ventilation duct 2 minus the wall thickness a of
the basic body 1. The inner surface of the ventilation duct 2 is
therefore formed partially from plastic 7 and partially from metal
comparably to the exemplary embodiment according to FIGS. 3a and
3b.
[0049] The first joining point 5 is situated directly on the outer
side of the basic body 1, on the left in FIG. 20a. Owing to the
fact that the plastic 7 on the inner side of the crossmember 1 is
displaced by the inner section 31 of the insert part 30, an
intermediate region 12 is also produced here between the joining
point 5 and the plastic 7 forming the wall of the ventilation duct
2. The core of a mold used during the injection molding method has
an outer diameter which corresponds to the inner diameter of the
ventilation duct 2. During the injection molding method the insert
parts 30 are therefore held fixedly in the basic body 1. Retaining
arms 32 which penetrate the basic body 1 in the case of the central
and right-hand insert parts 30 in the illustration extend
essentially radially outward from the inner sections 31 and the
joining parts 4 are welded to them as holders or connections for
further components.
LIST OF DESIGNATIONS
[0050] 1 Basic body, crossmember [0051] 2 Ventilation duct [0052] 3
Component [0053] 4 Joining part [0054] 5 Joining point, weld seam
[0055] 6 Embossed structure [0056] 7 Plastic [0057] 8 Knob [0058] 9
Outer side [0059] 10 Web [0060] 11 Inner side [0061] 12
Intermediate region [0062] 13 Hole [0063] 14 Bent-outward part
[0064] 15 Limb [0065] 16 Eyelet [0066] 17 Aperture [0067] 18 Rib
[0068] 19 Side wall [0069] 20 Base surface [0070] 21 Supporting
limb [0071] 22 Fastening limb [0072] 23 Hole [0073] 24 Hole [0074]
25 Embossed structure [0075] 26 Opening [0076] 27 Fastening arm
[0077] 28 Notch [0078] 29 Ribbed structure [0079] 30 Insert part
[0080] 31 Inner section [0081] 32 Retaining arm [0082] a Wall
thickness of the basic body [0083] b Wall thickness of the duct
[0084] c Embossed depth
* * * * *