# US 12,110,596 B2 · Structural element and method for producing a structural element

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- Number: US 12,110,596 B2
- Document ID: US12110596B2
- Status: Granted
- Kind: B2
- Application number: 17/291,648
- Filed: 2019-10-29
- Published: 2021-12-30
- Granted: 2024-10-08
- Earliest claimed: 2018-11-07
- Assignees: Bayerische Motoren Werke Aktiengesellschaft
- Applicants: Bayerische Motoren Werke Aktiengesellschaft
- Inventors: Manuel Anasenzl; Andre Hoevelmeyer; Dominik Paulke
- Web page: https://patentgrep.com/patent/US12110596B2

## CPC

- C23C 24/04: Impact or kinetic deposition of particles
- B23P 13/00: Making metal objects by operations essentially involving machining but not covered by a single other subclass (making specific objects B23P15/00)
- B23P 15/00: Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- B23P: METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS (arrangements for copying or controlling B23Q)

## Abstract

A structural part includes a pocket where the pocket is formed during or after a production of the structural part. A coating material is disposed in the pocket where the coating material at least partially fills the pocket. A method for producing a structural part includes removing or reducing material in a portion of a structural part to produce or form a pocket during or after a forming of the structural part and filling the pocket with a coating material by a coating method.

## Claims

### Claim 1

An aluminium die-cast structural part of a motor vehicle, comprising:
a pocket, wherein the pocket is formed during a casting of the aluminium die-cast structural part, wherein the pocket is defined entirely within peripheral walls formed by the aluminium die-cast structural part and a base formed by the aluminium die-cast structural part, and wherein the base is inclined toward a surface of the aluminium die-cast structural part such that there is no abrupt change in stiffness in the aluminium die-cast structural part;
a coating material disposed in the pocket, wherein the coating material at least partially fills the pocket and wherein the coating material is an iron-based material and wherein the coating material is disposed by cold gas spraying; and
a further structural part of the motor vehicle, wherein the further structural part of the motor vehicle is fastened to the iron-based coating material that is disposed in the pocket by a weld or an adhesive bond or a rivet or a screw.

### Claim 2 (depends on 1)

The structural part according to claim 1, wherein the coating material completely fills the pocket.

### Claim 3 (depends on 1)

The structural part according to claim 1, wherein a wall thickness of the structural part at the base is at least 1 mm.

### Claim 4 (depends on 1)

The structural part according to claim 1, wherein the pocket has a depth of at least 0.1 mm to the base.

### Claim 5

A method for producing an aluminium die-cast structural part of a motor vehicle, comprising the steps of:
forming a pocket during casting of the aluminium die-cast structural part, wherein the pocket is defined entirely within peripheral walls formed by the aluminium die-cast structural part and a base formed by the aluminium die-cast structural part, and wherein the base is inclined toward a surface of the aluminium die-cast structural part such that there is no abrupt change in stiffness in the aluminium die-cast structural part;
filling the pocket with a coating material by cold gas spraying, wherein the coating material is an iron-based material; and
fastening a further structural part of the motor vehicle to the iron-based coating material that is filled in the pocket by a weld or an adhesive bond or a rivet or a screw.