Daimler Chrysler Ag

Daimler Ag

Matthias Schroeder

Konrad Eipper

Jens Schult

Wilhelm Arns

Arndt Birkert

Kai-Uwe Dudziak

Roland Wendler

Helmut Augustin

Heinz Koslowski

Juergen Falke

Thomas Lohse

Hans Nottbusch

Thomas Sailer

Pierre Bonny

Eckhard Reese

Michael Bechtold

Hans-Peter Maier

Stefan Schwarz

Dieter Junge

Silke Langwaldt

In a method and apparatus for producing a composite component comprising a hollow profile and at least one injection-molded element, a hollow profile () is formed by means of internal high pressure fluid forming and is encapsulated with an injection molding material to form the injection-molded element. The hollow profile is expanded by means of internal high pressure in a closed combination tool comprising an internal high pressure forming tool element and an injection molding tool element, before it is encapsulated. The hollow profile is pressed on the tool engraving only locally in the region of the location to be encapsulated, keeping the outlet of the injection molding channel opening into the tool engraving clear.

Composite component and a method and device for producing the composite component

In a method and apparatus for producing a composite component, a tubular hollow section blank is placed into a die cavity of a combination tool comprising an inner high-pressure shaping tool and an injection-molding tool. The combination tool is filled with a fluid in such a way that the blank is wetted from the inside by the fluid, and the ends of the combination tool are sealed by two axial molding plugs. The filled blank is then expanded under pressure . The finished hollow section is plastic-coated in the same tool. The hollow section is emptied after shaping in the sealed state, at least until it is no longer dripping, the pressurized fluid being expelled under pressure from the hollow section through at least one discharge channel formed in the axial molding plugs.

Method and apparatus for producing a composite component

A roof frame arrangement of a motor vehicle has a front, a rear and two lateral roof frames, and a supporting device for a motor vehicle tailgate. The supporting device includes a tailgate hinge and at least one gas-filled compression spring. At least the lateral roof frame contains an inner shell and an outer shell connected to the latter. A hollow space is formed between the inner shell and outer shell. In order to provide a roof frame arrangement having increased stiffness, which can be produced in a simple and space-saving manner and with as few manufacturing tolerances as possible and in which a relatively great outlay on leakproofness is not required, it is proposed to form a rear end region of the lateral roof frame as a single-piece, circumferentially closed hollow profile which encloses the hollow space there and forms a receiving housing in which at least one of the hinge and the gas-filled compression spring is fitted.

Roof frame arrangement for motor vehicles

A rear roof frame of a motor vehicle has a tailgate which is fastened to the roof frame and includes an upper shell and a lower shell which is fitted to the latter. For the design of a rear roof frame, which, in spite of the shell-type construction, provides, in a simple manner and lightweight construction, sufficient torsional and flexural stiffness in order to withstand high mechanical stresses, it is proposed to arrange within the shell structure a hollow profile which leads in each case from the transition region to the lateral roof frame and parallel to the longitudinal extent of the structure, and emerges, at least at the end facing away from the lateral roof frame, in a knee which kinks in the front-end direction of the vehicle. The end of the rear roof frame forms a tubular hollow profile of the lateral roof frame, which is connected to the hollow profile of the rear roof frame.

Rear roof frame for motor vehicles

A method and an apparatus are provided for internal high-pressure forming of a workpiece in a closed internal high-pressure forming die. The workpiece is expanded owing to the internal high fluid pressure exerted by a pressure generator and coming to rest on the cavity of the forming die. The workpiece and the forming die form friction partners in the areas of contact. In order to improve process reliability during the internal high-pressure forming of workpieces and to expand the scope of the method, vibration is imparted directly to at least one of the friction partners by a vibration generator during forming.

Internal high pressure forming method for a workpiece

A device for manufacturing a hollow body from two plates. The device includes an internal high pressure forming tool having an interior surface defining a mold chamber corresponding to a shape of the hollow body. The forming tool being arranged to receive two plates resting against each other. An expansion lance is insertable between the plates via an axial drive, and the expansion lance and the axial drive forming a pushing plunger. The expansion lance has a pinching section along a circumferential contour, and the plates to be pinched are arranged between the pinching section and the forming tool. The expansion lance includes a feed bore communicable with a high pressure fluid source. The expansion lance defines an axial stop to abut axial edges of the plates. The axial stop has a radial periphery which is smaller than that of the mold chamber.

Device for manufacturing a hollow body from two plates

A method and a device for manufacturing a hollow body from two plates, which are placed against one another and inserted into an internal high pressure forming tool. After the forming tool is closed, a fluid is introduced under high pressure between the plates by way of an expansion lance inserted between the plates. The plates are expanded until they abut the interior surfaces of the forming tool that match the shape of the hollow body. To achieve a process-reliable manufacture of the hollow body, the plates, before any internal high pressure is developed, are pinched in the thickness direction along the circumference of the opening that surrounds the inserted expansion lance by cooperation between the dies of the forming tool and the circumferential contour of the expansion lance that is oversize relative to the location between the plates at which the expansion lance is introduced. During the expansion process produced by internal high pressure, plate material is pushed by way of a stop located on the expansion lance and abutting the plate edges, toward the mold chamber formed by the interior surfaces of the dies.

Process for manufacturing a hollow body from two plates

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Gruenendeich, Germany

Matthias Schroeder