• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    method of fabricating a structural element, particularly for a vehicle suspension the structural element (10) comprises a wrap (12) made of at least one layer of composite material comprising a fiber-reinforced polymer matrix, and a core (14) made ductile material, in particular metal, such as high-strength steel. advantageously, the wrapper (12) comprises two wrapper halves (12a, 12b) joined together, for example, by thermal melting of the respective polymeric matrices or by gluing with structural adhesives, and the core (14) is fixed within the wrapper (12).
    公开号:BR112012029510B1
    申请号:R112012029510-1
    申请日:2011-05-12
    公开日:2021-04-06
    发明作者:Andrea Santini；Piero Monchiero；Guido Borgna
    申请人:Sistemi Sospensioni S.P.A.；
    IPC主号:
    专利说明:

    [0001] [001] The present invention relates to a method for the manufacture of composite structural element, particularly, but not exclusively for use in a vehicle suspension.
    [0002] [002] The materials generally used in the mass production of components for vehicle suspensions such as, for example, automobile suspensions, are steel, cast iron and aluminum, for reasons of production cost and material performance (weight, stiffness) , fatigue resistance, resistance to limit load conditions). The use of composite materials for the production of automobile suspension components is traditionally limited to racing cars such as, for example, Formula 1 cars, or so-called super cars, since in this case the weight and performance requirements are greater importance than cost.
    [0003] [003] In the design of components for vehicle suspensions, in particular for automobile suspensions, a number of requirements in conflict with one another must be met. In particular, a car suspension component must be able to withstand certain types of loads (so-called fatigue loads), which represent the normal use of the vehicle, although under heavy conditions, these loads are applied alternately to the component and the latter it must not suffer from the formation of cracks or failures within a certain number of applied fatigue cycles. High-strength materials, such as fiber-based composite materials, are suggested in order to meet this requirement for fatigue strength and at the same time limit weight. Another structural requirement that must be met by the car's suspension component is that the component must be able to deform in a predictable and particular way under so-called “misuse” loads, that is, under “limit load conditions”. With such a tension the component must be able to deform, reacting with a certain reaction load and absorb a certain amount of energy, but the connection between the wheel and the vehicle must always be guaranteed. In particular, any possible failure must be confined to specified zones and must not occur below a specified amount of deformation. Ductile materials, such as steel, are suggested in order to fulfill these requirements for controlled deformation and the presence of a deformation test mark under the conditions of limit load.
    [0004] [004] US7159880 describes a structural element, in particular for a vehicle chassis, comprising an elongated body and a pair of connecting elements mounted at opposite ends of the elongated body, where the elongated body consists of a metal core in which the material fiber reinforced plastic is overmoulded by injection molding to provide the elongated body with a cross section having the desired shape. On the one hand, the use of a fiber-reinforced plastic material allows limiting the weight of the component and at the same time guarantees high mechanical properties, while on the other hand the use of a metallic core prevents the loss of functionality of the component even in the damage. Such a known solution is, however, affected by the disadvantage of using the overmoulding technique to produce the plastic material portion of the structural element making it possible to obtain only structural elements with a solid cross section. This inevitably involves limits on the designer's freedom to design the cross section of the element, limits that are excessively penalizing, for example, in the case of structural elements intended to be used for triangular suspension arms. As it is known, in fact, in order to increase the resistance of the structural element, it is necessary to increase the moment of inertia of the cross section of it, in other words, to transfer the material of the cross section to the most distant possible of the intermediate plane of the same , in the present case, of the metallic core, which results in an excessive increase in the total weight of the element.
    [0005] [005] Additional examples of structural elements comprising a metal core in which plastic material, if necessary reinforced with fibers, is overmoulded, are known from US6030570, WO 2003/039893 and WO 2003/039892. These structural elements also suffer from the same disadvantage discussed above with reference to US7159880.
    [0006] [006] US2004 / 0131418, describes a structural element comprising a first part of metal having a U-shaped cross section and a second part of plastic material which is attached to the first part to close the U-shaped cross section of the same forming thus, a hollow structural element having a closed cross section. The first and second parts are obtained separately from each other and are then joined together by folding the edge of the second part at the edge of the first part, using heat or ultrasound. If, on the one hand, this known solution offers the advantage of reducing the overall weight of the structural element due to one of the two parts of which the element consists of being made of plastic material, instead of metal, on the other hand the weight reduction allowed by this The known solution is minimal, since the cross section of the structural element is basically formed by the first part, that is, by the metallic part.
    [0007] [007] It is, therefore, an objective of the present invention to provide a composite structural element that is capable of offering similar or better performances with respect to the prior art, with a lower weight.
    [0008] [008] This and other objectives are fully achieved according to the invention by virtue of a method for the manufacture of structural element according to independent claim 1 in the annex.
    [0009] [009] Advantageous modalities of the invention are defined in the dependent claims, the content of which is to be conceived as an integral and integral part of the description below.
    [0010] [010] In summary, the invention is based on the idea of providing a structural element comprising a wrap and a core, wherein the wrap comprises a first and second wrap halves made of at least one layer of composite material comprising a polymeric matrix fiber-reinforced and where the core is made of a ductile material, in particular metal. In the description and claims that follow, the term “wrapper” must be conceived as referring to any type of body defining at least one cavity, in which such a body can indifferently have both a closed cross section and an open cross section (in which case , of course, the wrap will not be a flat element). The simultaneous presence of a material having high mechanical properties (wrapping material) and a ductile material (core material) allows to meet, at the same time, the requirements of fatigue resistance, reaction load, deformation modality and presence of a deformation core mark under limit load conditions. The fatigue strength and the reaction load under limit load conditions are guaranteed in particular by the high-strength material of the wrap, and in that respect the wrap will be suitably shaped to provide the element with the necessary inertia characteristics each time for the specific application . The ability to absorb impact energy, the ability to provide a deformation test mark and the ability to prevent failure in order to lead to the separation of the parts are guaranteed, on the other hand, by the ductile material of the core. The use of composite material for the wrapping of the structural element, which forms the main portion of the structural element in terms of material volume, clearly allows the reduction of the overall weight of the element with respect to the prior art.
    [0011] [011] The polymeric hue of the composite wrap material may consist of a thermoplastic polymer or a thermoset polymer (such as, for example, epoxy resin). The fibers of the composite wrapper material can be oriented fibers or short, randomly oriented fibers. Carbon fibers, Kevlar fibers, glass fibers, metal fibers or fibers of any other material adapted to provide the composite material with the required high mechanical properties can be used. In the case of a casing made as a body with a closed cross section, it is advantageous to comprise two casing halves joined together by heating to a temperature such as to cause the polymeric matrix of the composite material to melt. Heat can be provided by contact with hot surfaces (for example, with a heat-regulated mold) or by laser welding.
    [0012] [012] The core is advantageously made of rolled metal, in particular a sheet of high-strength steel, and is suitably shaped to have protrusions or changes in plane, if required due to structural reasons. The core can be made as a single piece obtained, for example, by stamping or, alternatively, it can comprise a plurality of separate pieces that are each obtained, for example, by stamping and are securely connected to each other by various joining techniques, for example, by welding, rivet or glue.
    [0013] [013] Since the structure element comprises a part (that is, the part made of composite material) made as a wrap, the empty spaces are present between the wrap and the core, empty spaces that can be connected indifferently to each other to form a single cavity or form separate cavities. The cavities between the core and the wrap can be filled with filling material having the function of providing the structural element with ductility and / or mechanical resistance. Of course, the filling material can also be supplied only in some of the cavities.
    [0014] [014] When used as a component for a vehicle suspension, the structural element can be supplied with one or more connecting elements, such as pivot bushings. For this purpose, the structural element additionally comprises one or more cylindrical pins or sleeves, each intended to form a seat for the respective bushing. When the core of the structural element is made of metal, cylindrical sleeves can also be made of metal and welded directly to the core. Alternatively, the cylindrical sleeves can be glued, or joined in any other way, to the envelope of the structural element.
    [0015] [015] Additional features and advantages of the present invention will appear more clearly from the following detailed description of a preferred embodiment thereof, provided purely by way of non-limiting example with reference to the accompanying drawings, in which:
    [0016] [016] Figures 1 and 2 are a perspective view and a plan view, respectively, of a triangulation arm for an automobile suspension as an example of a structural element according to the present invention;
    [0017] [017] Figure 3 is a sectional view of the triangular arm of figures 1 and 2 through the section plane indicated III-III in figure 2;
    [0018] [018] Figure 4 is a sectional view of the triangulation arm of figures 1 and 2 through the section plane indicated IV-IV in figure 2;
    [0019] [019] Figure 5 is a sectional view of an alternative embodiment of a structural element according to the present invention; and
    [0020] [020] Figure 6 is a sectional view of a modality of a structural element that is not part of the present invention.
    [0021] [021] Initially, with reference to figures 1 to 4, the number 10 generally indicates a triangular arm for an automobile suspension as an example of a structural element according to the present invention. However, as already mentioned in the introductory part of the description, the invention is applicable to any other structural element for a vehicle, not necessarily an element intended to be used as a suspension component.
    [0022] [022] The arm 10 basically comprises a wrapper 12 of composite material, a core 14 (figures 3 and 4) of ductile material and a plurality of seats (in this case, three seats) to receive, in each one, a respective connection element (not shown), such as a bushing or spherical joint, for connecting the arm on the one hand to the wheel carrier (not shown) and on the other hand to the vehicle body (also not shown).
    [0023] [023] As mentioned in the introductory part of the description, the wrapper 12 is a body that is shaped so as to define at least one cavity and, in particular, in the example illustrated in the drawings it is a hollow body having a closed cross section. Wrap 12 is made of at least one layer of composite material having a fiber-reinforced polymer matrix. The polymeric matrix may consist of a thermoplastic polymer or a thermosetting polymer (such as, for example, epoxy resin), while the fibers may be oriented fibers, for example, carbon fibers, Kevlar fibers, glass fibers, fiberglass fibers metal or fibers of any other material suitable to provide the composite material with the necessary high mechanical properties, or randomly oriented short fibers (in other words, unoriented short fibers). In the case of oriented fibers the wrap will advantageously be made up of more layers of composite material superimposed on each other, whereas in the case of short unoriented fibers the wrap will consist of a single layer of composite material. Naturally, the orientation of the fibers (in the case of oriented fibers), as well as the texture of the fiber and the sequence of overlapping of several layers, will be chosen in order to provide the wrap with the desired mechanical properties. As can be seen in Figures 3 and 4, in the case of a wrapper 12 made of a hollow body having a closed cross section, it consists of two or more pieces that are produced separately from each other and are then joined together in order to obtain a closed cross section. In the proposed example, wrapper 12 consists of two wrapper halves 12a and 12b, that is, an upper wrapper half and a lower wrapper half, respectively. The two casing halves 12a and 12b are advantageously joined to each other by heating to a temperature so as to cause the polymeric matrix of the composite material to melt. In this case, heat can be provided by contact with hot surfaces (for example, with a temperature-regulated mold) or by laser welding. Alternatively, the two wrap halves 12a and 12b are glued together with suitable structural adhesives.
    [0024] [024] Core 14 is preferably made of metal as a ductile material, in particular, high strength steel. However, the core 14 can also be made of non-metallic material, as long as it has suitable properties in terms of resilience and ductility. In the example of figures 1 to 4, where the wrapper 12 is a hollow body having a closed cross section, the core 14 is inserted and fixed within the wrapper. Preferably, the core 14 extends substantially over the entire plane of the structural member 10, in addition to the end zones of the member where the seats mentioned above are provided. Alternatively, the core 14 can, however, extend only in certain areas of the structural element, in particular in the zone of controlled deformation, where there may be risks of failure of the envelope with loss resulting from the continuity of material of the element. The core 14 is advantageously made of laminated metal and is suitably shaped so as to have projections and / or changes in plane where it is necessary due to structural reasons. As can be seen in the sectional view of figure 3, the core 14 has, for example, a cross section forming a straight intermediate section and, at the opposite ends of the intermediate section, a pair of tabs 16 bent at an angle, for example, at a right angle to the middle section. On the one hand, the tongues 16 have the function of increasing the bending stiffness of the core 14. On the other hand, in the case of the wrap 12 being obtained by the union of the two wrap halves 12a and 12b, the tongues 16 have the function of supporting the upper wrap half during the step of joining the two wrap halves, when this step is carried out by heating. However, tongues 16 may not even be present. The core 14 can be made as a single piece, obtained, for example, by stamping, or alternatively it can comprise a plurality of separate pieces that are each obtained, for example, by stamping and are securely connected to each other by various techniques joining, for example, by welding, rivet or glue.
    [0025] [025] The core 14 is joined to the wrapper 12 in the flat intermediate parts of the structural element (straight intermediate section of the cross section of the structural element illustrated in figure 3). The junction between the core 14 and the wrapper 12 is achieved by gluing or riveting. In the case of a core 14 having side tabs 16, the core can be attached to the casing 12 also on those tabs. Furthermore, the core 14 may have holes or partitions, in which case the casing halves 12a and 12b will be in contact with each other and will be joined by glue or rivet in these holes or partitions.
    [0026] [026] The casing 12 and the core 14 are shaped in such a way that empty spaces are defined between these two components, which spaces can be indifferently connected to each other to form a single cavity or to form separate cavities. In structural element zones where the core is not present, the cavities will be closed only by the wrapping material, instead of being closed partly by the wrapper and partly by the core. The cavities mentioned above can be filled with filling material having the function of providing the structural element with ductility and / or resistance. In this regard, figure 4 illustrates a cavity (indicated 30 and located around one of the arm seats mentioned above) that is filled with the filling material.
    [0027] [027] In the proposed modality, in which the structural element is a suspension arm, in particular a triangular arm, the structural element is provided with one or more connecting elements (in this case, three connecting elements) such as articulation. For this purpose, the arm 10 comprises three cylindrical tubular sleeves or elements 18, 20 and 22, of which the first two have a vertical geometric axis and the third has a horizontal geometric axis, and which must each form a seat for activate the respective articulation bushing. The cylindrical sleeves 18, 20 and 22 can also be made of metal and can be welded directly to the core 14. In addition to or as an alternative to be attached to the core 14, the cylindrical sleeves 18, 20 and 22 can be glued or joined in any other way to wrap 12.
    [0028] [028] Reinforcement layers 24 of composite material can also be attached to the wrap 12 and are advantageously made of the same material as the wrap. The reinforcement layers 24 can be fixed to the wrapper 12 by melting or gluing. A localized reinforcement of the arm in the areas subject to higher tensions is thus obtained.
    [0029] [029] With reference to figures 5 and 6, where parts and elements identical or corresponding to those in figures 1 to 3 received the same numerical references, two examples of alternative modalities of a structural element are illustrated. Unlike the modality of figures 1 to 4, where the two wrap halves 12a and 12b are joined to each other with their respective edges (indicated by 26a for the upper wrap half and 26b for the lower wrap half in figures 3 and 4) arranged in a butt, in the embodiment of figure 5, the two casing halves 12a and 12b are joined to each other with the respective edges 26a and 26b overlapping each other. In addition, as specified above, the two wrapper halves 12a and 12b can be joined together, by gluing or riveting, also in the holes or partitions provided in the core 14. In the embodiment of figure 6, the wrapper 12 of the structural element is made as a single piece of composite material with an open cross section and the core 14 is fixed to the wrapper 12, in particular, by gluing tabs 16 of the core to the edges 26 of the wrapper, so as to form with the latter an element having a closed cross section.
    [0030] a) fornecimento de um envoltório 12 feito de pelo menos uma camada de material compósito compreendendo uma matriz polimérica reforçada com fibra; b) fornecimento de um núcleo 14 feito de um material dúctil; e c) união do núcleo 14 ao envoltório 12. [030] The following steps are basically provided for the manufacture of a structural element according to the invention: a) providing a wrapper 12 made of at least one layer of composite material comprising a fiber-reinforced polymer matrix; b) providing a core 14 made of a ductile material; and c) joining the core 14 to the wrapper 12.
    [0031] [031] In the event that the wrapper 12 is made as a hollow body having a closed cross section comprising two wrapper halves 12a and 12b, step (a) provides the two wrapper halves 12a and 12b being obtained separately from each other, a step (c) provides the core 14 being joined to one of the two wrap halves (the wrap half 12b in the embodiment of figure 3 and the half wrap 12a in the embodiment of figure 5) and an additional step (d) will also be provided , in which the second casing half is joined to the first casing half and, if necessary, also to the core 14. In this regard, as already mentioned, the two casing halves 12a and 12b are advantageously joined to each other by heating to a temperature in order to cause the polymeric matrix of the composite material to melt, the heat required to cause the polymeric matrix of the composite material to be melted by contact with hot surfaces (eg with a regular mold) temperature) or by laser welding. Alternatively, the two wrap halves 12a and 12b can be glued together with suitable structural adhesives.
    [0032] [032] With respect to step (b), as already noted above, the core 14 can be produced as a single piece obtained, for example, by stamping, or can alternatively comprise a plurality of separate pieces, which are each obtained, for example, by stamping or are securely connected to each other with various joining techniques, for example by welding, rivet or glue.
    [0033] [033] Naturally, the principle of the invention remains unchanged, the modalities and details of construction may vary widely with respect to those described and illustrated purely by way of non-limiting example, without thereby departing from the scope of the invention as defined in the claims attached.
    权利要求:
    Claims (6)
    [0001]
    Method of manufacturing a structural element (10), particularly for a vehicle suspension, FEATURED by the fact that it comprises the steps of: (a) providing first and second separate wrap halves (12a, 12b) made of at least one layer of composite material comprising a fiber-reinforced polymer matrix; (b) providing a core (14) made of ductile material; (c) joining the core (14) to the first casing half (12a) in such a way that at least one cavity (30) is defined within the structural element (10); and (d) joining said second wrap half (12b) to the first wrap half (12a).
    [0002]
    Method according to claim 1, CHARACTERIZED by the fact that said first and second wrap halves (12a, 12b) are joined together by heating to a temperature such as to cause the polymeric matrix of the composite material to melt .
    [0003]
    Method according to claim 1, CHARACTERIZED by the fact that the first and second wrap halves (12a, 12b) are joined to each other by gluing.
    [0004]
    Method, according to any of the preceding claims, CHARACTERIZED by the fact that the core (14) is made as a single piece.
    [0005]
    Method according to any one of claims 1 to 3, CHARACTERIZED by the fact that the core (14) is made by joining a plurality of separate parts.
    [0006]
    Method according to any one of the preceding claims, CHARACTERIZED by the fact that it additionally comprises the step of filling said at least one cavity (30) with filling material.
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    法律状态:
    2018-12-26| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-11-12| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-06-23| B15K| Others concerning applications: alteration of classification|Free format text: AS CLASSIFICACOES ANTERIORES ERAM: B60G 7/00 , B62D 29/04 , B62D 21/00 , E04C 3/00 , B29D 24/00 , B62D 29/00 , B62D 65/00 Ipc: B29C 33/38 (2006.01), B62D 29/04 (2006.01), B62D 2 |
    2021-02-17| B09A| Decision: intention to grant|
    2021-04-06| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 12/05/2011, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    ITTO2010A000395A|IT1400618B1|2010-05-12|2010-05-12|STRUCTURAL ELEMENT IN COMPOSITE MATERIAL, PARTICULARLY FOR VEHICLE SUSPENSION|
    ITTO2010A000395|2010-05-12|
    PCT/EP2011/057676|WO2011141538A1|2010-05-12|2011-05-12|Composite structural element, particularly for a vehicle suspension, and method for manufacturing the same|
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