# US 8,465,084 B2 · Bodyshell structure for a motor vehicle and method for the production thereof > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,465,084 B2 - Document ID: US8465084B2 - Status: Granted - Kind: B2 - Application number: 12/994,889 - Filed: 2009-03-13 - Published: 2011-04-07 - Granted: 2013-06-18 - Earliest claimed: 2008-06-09 - Assignees: Daimler AG - Applicants: Karl-Heinz Ilzhoefer; Asmir Salkic - Inventors: Karl-Heinz Ilzhoefer; Asmir Salkic - Web page: https://patentgrep.com/patent/US8465084B2 ## CPC - B62D 29/043: {Superstructures (B62D25/161 takes precedence)} - B29C 70/30: Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core - B29C 70/86: Incorporated in coherent impregnated reinforcing layers, {e.g. by winding} - B62D 25/00: Superstructure {or monocoque structure} sub-units; Parts or details thereof not otherwise provided for {(having impact absorbing means B62D21/15; running-boards, steps, or the like as superstructure sub-unit B60R3/00)} - B62D 29/046: {Combined superstructure and frame, i.e. monocoque constructions} - B29L 2031/3055: {Cars} - B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract The invention relates to a method for the production of a bodyshell structure for a motor vehicle, wherein a sheet-like textile support element impregnated with a curable matrix material is provided and, following the positioning of suitable reinforcing and molding elements, molded around at least one mold core, whereupon the matrix material is cured. After the removal of the at least one mold core, a single-piece bodyshell structure joined by adhesive force remains. The invention further relates to a bodyshell structure produced by means of this method. ## Claims ### Claim 1 A method for the production of a cellular bodyshell structure (52) for a motor vehicle, comprising the following steps: a) providing a sheet-like textile support element (12) made of reinforcement fibers, which is impregnated with a curable matrix material, b) positioning reinforcing and molding elements (36, 38, 40, 42, 44, 46, 48) made of a fibrous material of reinforcement fibers, which is impregnated with a curable matrix material, on the support element (12), c1) shaping the support element (12) around at least one mold core corresponding to the contour of the cellular bodyshell structure, c2) joining all mutually adjoining elements by adhesive force to form a single-piece structure, d) curing of the matrix material, e) removing the at least one mold core. ### Claim 2 (depends on 1) The method according to claim 1, wherein the mold core laterally supports at least one side frame of the cellular bodyshell structure, which comprises a frame-like aperture panel (30), a door frame (32) and at least one pillar (34). ### Claim 3 (depends on 2) The method according to claim 2, wherein the side frame is joined to the elements and integrated into the single-piece structure in step c2). ### Claim 4 (depends on 2) The method according to claim 2, wherein reinforcing and molding elements (36, 38, 40, 42, 44, 46, 48) are used, the fibrous material of which at least partially surrounds a supporting element (50) made of foam or of a material with a honeycomb structure. ### Claim 5 (depends on 1) The method according to claim 1, wherein reinforcing and molding elements (36, 38, 40, 42, 44, 46, 48) are used, the fibrous material of which at least partially surrounds a core which can be removed after curing in step d). ### Claim 6 (depends on 1) The method according to claim 1, wherein at least one of the reinforcing and molding elements (36, 38, 40, 42, 44, 46, 48) or the side frame is partially made of at least one of aluminium and steel. ### Claim 7 (depends on 1) The method according to claim 1, wherein at least one side of the mold core is left free in the molding process of the support element (12). ### Claim 8 (depends on 1) The method according to claim 1, wherein the mold core is provided with guidance means selected from grooves, edges and moldings, for attaching the reinforcing or molding elements. ### Claim 9 (depends on 1) The method according to claim 1, wherein at least one of clamping and fixing means for fixing the molding elements are fitted after or during the molding of the support element (12) around the at least one mold core. ### Claim 10 (depends on 1) The method according to claim 1, wherein for an additional fixing of the molding elements, the support element (12) is moulded around the at least one mold core under tension. ### Claim 11 (depends on 1) The method according to claim 1, wherein further reinforcing and molding elements (36, 38, 40, 42, 44, 46, 48) are fitted between steps c1) and d). ### Claim 12 (depends on 1) The method according to claim 1, wherein a support element (12) with cut-outs for at least one of door (16) and window openings (14) is used. ### Claim 13 (depends on 1) The method according to claim 1, wherein the reinforcement fibers of at least one of the textile support element (12) and the reinforcing and molding elements (36, 38, 40, 42, 44, 46, 48) are oriented optimally in terms of power flow and tension. ### Claim 14 (depends on 1) The method according to claim 1, wherein following the molding of the support element (12) in step c1), connecting elements are joined by at least one of sewing and adhesive bonding to the at least two reinforcing and molding elements (36, 38, 40, 42, 44, 46, 48) at at least one contact point between least two reinforcing or molding elements (36, 38, 40, 42, 44, 46, 48). ### Claim 15 (depends on 1) The method according to claim 1, wherein the reinforcing and molding elements (36, 38, 40, 42, 44, 46, 48) positioned on the support element (12) in step b) are joined to the support element (12) by at least one of sewing and adhesive bonding. ### Claim 16 (depends on 1) The method according to claim 1, wherein connecting elements for joining adjacent components are fitted to the support element (12) before the curing process in step d). ### Claim 17 (depends on 1) The method according to claim 1, wherein the reinforcing and molding elements (36, 38, 40, 42, 44, 46, 48) form a space frame structure after the curing process in step d). ### Claim 18 (depends on 1) The method according to claim 1, wherein the curing process in step d) is based on at least one of thermal-initiation, photo-initiation, a cold cure, and the application of pressure and pressing. ### Claim 19 (depends on 1) The method according to claim 1, wherein the matrix material is chosen from the group including thermally, cold- or UV-curing polyester, polyurethane, epoxy and phenolic resins and vinyl ester. ### Claim 20 (depends on 1) The method according to claim 1, wherein at least one of glass fibers, carbon fibers, aramide fibers, polyethylene fibers, ceramic fibers, metal fibers and natural fibers is chosen as reinforcement fibers. ### Claim 21 (depends on 1) The method according to claim 1, wherein at least one mold core made of at least one of metal, sand, wood, plastic and cardboard is used. ### Claim 22 A cellular bodyshell structure (52) for a motor vehicle, wherein the bodyshell structure is a single-piece component represented by a composite of a sheet-like support element (12) and a plurality of reinforcing and molding elements (36, 38, 40, 42, 44, 46, 48) made of a fibrous composite material and joined by adhesive force. ### Claim 23 (depends on 22) The bodyshell structure according to claim 22, wherein the reinforcing elements (36, 38, 40, 42, 44, 46, 48) are arranged in the form of a space frame structure, and wherein the single-piece bodyshell structure comprises at least one side frame with a frame-like aperture panel (30), a door frame (32) and at least one pillar (34). ### Claim 24 (depends on 22) The bodyshell structure according to claim 22, wherein at least one of the reinforcing elements (36, 38, 40, 42, 44, 46, 48) has a core (50) made of a material selected from the group consisting of a foam and a material having a honeycomb structure. ### Claim 25 (depends on 22) The bodyshell structure according to claim 22, wherein at least one of the reinforcing elements (36, 38, 40, 42, 44, 46, 48) has an internal cavity. ### Claim 26 (depends on 22) The bodyshell structure according to claim 22, wherein a connecting element is provided between at least two adjacent elements selected from the group consisting of reinforcing elements and molding elements (36, 38, 40, 42, 44, 46, 48). ### Claim 27 A motor vehicle having a bodyshell structure wherein the bodyshell structure is a single-piece component represented by a composite of a sheet-like support element (12) and a plurality of reinforcing and molding elements (36, 38, 40, 42, 44, 46, 48) made of a fibrous composite material and joined by adhesive force.