DE19956607A1 - Plastic compound building element comprises at least two parts consisting of different materials, and incorporates a joint zone consisting of a thermoplastic material - Google Patents

Abstract

The plastic compound building element comprises at least two parts (1, 2) consisting of different materials, and incorporates a joint zone (6) consisting of a thermoplastic material which penetrates or interlockingly surrounds at least one to the two parts. Also claimed is a range of possible applications for such a building element.

Description

The invention relates to a plastic composite component consisting of at least two flat workpieces made of different materials, e.g. B. of metal and Plastic, different metals or different plastics, which are connected to one another in their edge region, characterized in that the Connections of the workpieces made of molded thermoplastic consists.

The form-fitting combination of flat components from different plants fabrics, is achieved by forming a thermoplastic material.

The composite component fulfills different technologies in different areas functions. It connects z. B. high-strength, temperature-resistant and KTL-go components with tailor-made workpieces in functional zones.

Composite components or semi-finished products used in practice consist of e.g. B. surfaces adhere to bonds where z. B. two metal sheets with the help of one in between plastic or plastic foam connected to a sandwich structure (see EP 489 320 A1, EP 285 974 A1 and EP 547 664 A2). Furthermore there are processes for the production of composite panels with external sheets and internal rib structure (see EP 775 573 A2). There is also a ver drive to join sheet metal by a combination of presses and spray pour in one tool (EP 721831 A1). There is also art Known fabric / metal composite components in which metal sheets by rib structure doors are supported (EP 370 342 A3).

The composite customary in the prior art or described in the literature Components and semi-finished products are designed to cover the entire component  uniform high strength and rigidity or sound and heat insulation to reach.

However, certain special applications require e.g. B. a plate that on different locations of the plate fulfilled different technical characteristics Need to become. This can mean that there is insulation on half of the board Function is required and only with the other half of the same component Connections to other separate components or structural elements or that Closing openings should be achieved. In this case, e.g. B. Conven used composite panels, the component is overall overdetermined Lich its functions and therefore too difficult or too complex to manufacture.

The invention is therefore based on the object of a composite component of the introduction to create the kind mentioned in the different areas of the component the special ones required for the respective functions of the component acoustic, mechanical, optical or other material properties other connects.

This object is achieved in that a component is created is made up of at least two different areas in different Materials are made, which consists of reshaping a thermoplastic Plastic are positively connected.

The invention relates to a plastic composite component consisting of mindes at least two flat workpieces made of different materials, in particular different metal, different plastic, or metal and art Fabric parts that are connected to each other in their edge area, characterized thereby records that the connection point made of molded, in particular molded thermoplastic material and in particular at least one workpiece penetrated by the thermoplastic in the area of the connection point is enclosed or positively enclosed.  

Suitable high-strength metal materials are steel, aluminum, magnesium, questionable. The workpieces can also be made of ceramic, thermosets or plastic Composite materials exist.

As a thermoplastic, both as a material for the workpieces and for the Connection point, come unreinforced or reinforced, possibly filled Plastics such as polyamide, in particular polyamide-6, polyamide-6.6, polyamide-12, Polyamide-11 or polyester, especially polyethylene terephthalate, polybutylene terephthalate, or polyolefins, especially polypropylene, styrene copolymers, in particular SAN resin or ABS, or polycarbonate, polypropylene oxide, polyphe nylon sulfide, polyimide, PSO or PEEK or from possible mixtures of ge named plastics in question.

The composite component is a predominantly flat hybrid component, that can also contain linear or punctiform functional elements. To pots tial connection points to other components are preferably defined joints rich provided, both in shape, location and size as well as in terms of Material can be designed variably.

In a preferred form of the composite component, one or more plants have pieces of the composite component in the area of the connection openings or Recesses through which molded thermoplastic material runs through are and form a positive connection of the workpieces.

A particularly preferred embodiment of the composite component is characterized records that one of the workpieces made of the same thermoplastic how the place of use exists.

In a preferred embodiment, one of the workpieces consists of an elasto mer, in particular a thermoplastic elastomer. Such components are  e.g. B. accessible by the basically known two-component injection molding technology Lich.

The elastomer is preferably thermoplastic polyolefin.

If necessary, one of the Workpieces of the component for shielding electromagnetic radiation from one Made of metal that is connected to other non-metallic workpieces.

Workpieces of the composite component according to the invention on one of the composite component of different construction or other components should be connected len, can be freely designed according to the suitable joining or connection technology be chosen.

If the plastic composite component according to the invention z. B. with a steel frame welded, the workpiece abutting the frame becomes a weldable steel sheet.

In this way it becomes possible to use the entire plastic ver according to the invention collar component in different places with completely different connections attaching techniques to external components or structures, e.g. B. means Metal welding and plastic friction welding.

Another object of the invention is the use of Plastic composite component as a construction element for machines and vehicles, in particular motor vehicles, for electronic articles, household articles or for the Building needs.

The workpieces are in the form of sheets, sheets, plates, profiles (open or closed profiles) or hollow chambers. Type of material, An The number and shape of the workpieces can be varied as required. In a before  tensile execution are flat workpieces, z. B. metal sheets and plastic panels, positively connected at their edges. For this purpose, in Area of overlapping openings at the rivet connection point Molded heads made of thermoplastics, which provide a firm connection to the high-strength Enable workpiece (e.g. sheet metal).

In this way, several high-strength workpieces can be connected to each other become. The function of the plastic on the holding together high-strength workpieces in the form of rivet heads.

It is also possible to create a composite component that consists of several there are directly connected high-strength workpieces that also with Means plastic rivet connections are secured, the plastic component but also z. B. in the form of a molded plastic plate, other tasks takes.

By attaching flexible components made of flexible thermoplastics, thermoplastic elastomers or elastomers between high-strength, inflexible or rigid areas of the composite component, the dynamic behavior of the Ge velvet component improved or the assembly of the component easier. Furthermore can by the formation of the flexible workpieces as a film hinge the component partially movable.

At isolated points of a component, shielding from electromagnetic shear radiation can be achieved by using metal sheets as the workpiece be with z. B. thermoplastics or other non-metallic workpieces.

Possible connection points of the component according to the invention to other components or constructions, through the positive connection of the individual  Workpieces in all known materials. The The joining process can thus be freely selected.

When choosing a high temperature resistant plastic (polyamide, poly butylene terephthalate, polyethylene terephthalate, polypropylene oxide, PSO, polyphenylene sulfide, polyimide, PEEK or mixtures of these materials in unreinforced or unfilled as well as in fiber-reinforced or filled version) can be combined with the form-fitting joining of the workpieces a high temperature resistance as well as a KTL compatibility of the composite component can be achieved.

The composite component can be produced in different ways. The type of connection differs mainly from e.g. B. Plastic and high-strength component (metal workpiece):

• 1. Form-fitting connection of plastic workpiece and high-strength workpiece by material forming.
  In this manufacturing process, the connection can be achieved by injection molding as well as by plastic riveting by means of previously formed connecting elements. In both cases, the high-strength workpiece is provided with openings in the area of the connection point (e.g. sheet metal with holes in the edge area) through which thermoplastic plastic penetrates and a positive connection is thus achieved.
  When connecting by injection molding, z. B. inserted a metal sheet into an injection mold. The injection molding process both a less solid workpiece in the form of z. B. generates a plate and also reached the connection to the metal sheet. Since the plastic material is filled into the injection mold in liquid form, it can flow through the openings in the metal sheet and form rivet heads on the back of the metal sheet. In this way, different parts made of metal or composite materials can be connected to one another directly or indirectly via areas made of thermoplastic material in one process step.
  Similarly, even when using plastic riveting, a connection to a less rigid workpiece to a high-strength workpiece can be aimed at. The thermoplastic is first injection molded separately in a mold without metal sheet, but with molded connecting pins. Then one or more metal sheets are placed on the plastic part, the connecting pins protrude through previously made openings in the metal sheet or sheets. The connecting pins are then formed into a rivet head using a forming process (e.g. using ultrasonic welding). In addition, the weld connection can be carried out using separate additional elements (e.g. stud welding) or achieved by joining two thermoplastic workpieces with molded connecting elements.
• 2. Positive connection of a thermoplastic workpiece with a high-strength workpiece through plug-in or snap connections. With this First, a plastic workpiece is produced, which he uses required plug or snap elements is equipped. For this, e.g. B. an injection molded plastic part with molded pins who used the one that is inserted into prepared openings in the high-strength workpiece become.

There are other ways of connecting the workpieces in use different combinations of the methods mentioned. So there is Possibility to achieve positive locking between the high-strength workpieces in the congruent beads are attached in both parts. About one too additional congruent breakthrough in both high-strength workpieces  a riveted joint, e.g. B. by reshaping molded on the plastic part Ver binding pin, are attached.

The advantages that can be achieved with the invention can be summarized as follows:
The composite component enables a composite surface made up of workpieces with any materials that can be varied.

There is the possibility of designing composite structures according to requirements share with partially different types and levels of stress.

The invention enables the cost and weight-optimized design of composite components with partially different property profiles.

The invention also enables the joining method to be freely selected for connection with other components and construction elements as well as the production of a Composite of different materials in one process step. The composite components according to the invention find a lot in a corresponding design extensive use as a construction element for machines, vehicles and components of all kinds, in particular for motor vehicles, for electronic articles, household articles and for building needs.

Structural parts for power are particularly suitable applications of the composite component vehicles doors, bumpers, beams, front and rear parts for cars, door sills supporting frame as well as decorative elements which have increased strength with others Connect material properties.

The invention is explained in more detail below with reference to figures. Show it  

Fig. 1 is a plate 1 made of thermoplastic material, to which a steel sheet 2 is connected by positive locking.

Figure 2 shows the connection of two high-strength workpieces on a medium solid work piece made of plastic.

FIG. 3 shows the connection of several metal sheets on a work piece made of thermoplasti schem polyurethane;

Fig. 4 shows the detail from a floor group in the tunnel area of a motor vehicle.

Examples example 1 Composite with partially different functions ( Fig. 1)

Fig. 1 shows a plate 1 made of a thermoplastic material to which a steel sheet 2 is connected at its left end via positive connections 6 for absorbing point-acting forces. The left half of plate 1 is provided with a foam 3 on its top for sound insulation. On the right half of the plate 1 , the plate 1 is supported by two lying U-profiles 5 made of aluminum and an integrated rib structure 4 made of the same material as the plate 1 to accommodate larger surface loads. The plate 1 , the rib structure 4 and all positive connections 6 of the connection points are formed by the thermoplastic component.

The composite component can be manufactured in two different ways. On the one hand, there is the possibility of inserting the sheet 2 , the foam 3 and the U-profiles 5 into an appropriately shaped injection molding tool and then injecting the thermoplastic component, with which the plate 1 , the rib structure 4 and the positive connections 6 are then produced. When the melt solidifies in the injection molding process, the individual components are firmly connected to one another. In a second variant, the plate 1 with the integrated rib structure 4 and the pins required for the positive connections 6 is first produced. Then the components sheet metal 2 , foam 3 and U-profiles 5 are placed on the plate 1 in such a way that the pins of the plate 1 fit into the prepared openings of the components 2 , 3 and 5 . The pins are then ultrasonically welded to form 6 .

Example 2 Cross section through a composite of three metal sheets ( Fig. 2)

In Fig. 2 is shown how different high-strength workpieces (metal sheets) may be directly connected. The metal sheets are deformed at the connection points seen before which are provided with openings 14 so that the resulting domes 11 can be inserted into the holes in the metal sheet 10 . By filling the remaining bore 14 with the thermoplastic material by means of injection molding or ultrasonic forming of inserted connecting elements, a riveted connection 6 is obtained which ensures the positive connection of the various metal sheets 2 , 10 .

Example 3 Cross section through a flexible composite of sheet metal and thermoplastic elements ( Fig. 3)

In this example, two metal sheets 2 are flexibly connected to one another by an elastic plate 9 made of thermoplastic polyurethane. The connection is formed by means of positive connections 6 , which consist of the same material as the plate 9 , in accordance with the explanations of Example 1 or 2. About a thermoplastic element 16 made of rigid plastic material, another metal sheet 12 is connected to the composite in a different plane. The elastic plate 9 and the thermoplastic element 16 can be molded in one step by two-component injection molding of the metal molds inserted into the injection molding tool.

Example 4 Cross section through a vehicle floor assembly ( Fig. 4)

Fig. 4 shows the detail of a floor group in the tunnel area of a vehicle. The bottom plates 2 , the tunnel plate 7 and the tunnel cover 8 are each made of steel and are connected to one another via the thermoplastics 17 . The workpieces 2 and 7 are inserted into an injection mold and partially overmolded in their edge area with a thermoplastic. At the same time, connecting pins are formed, which are formed into rivet connections 6 by means of ultrasonic welding after the tunnel cover 8 has been placed on them.

According to this procedure, floor panels can also be used with vehicles Bulkhead or side members connected to floor panels in the sill area become.

Claims (8)

1. Plastic composite component consisting of at least two flat work pieces ( 1 ) and ( 2 ) made of different material, in particular under different metal, different plastic or metal and plastic parts that are connected to each other in their edge region ( 13 ), characterized in that the Connection point ( 6 ) consists of molded, in particular molded, thermoplastic material and in particular at least one workpiece ( 1 ) or ( 2 ) in the area of the connection point ( 6 ) is penetrated by the thermoplastic material or is positively enclosed. 2. Plastic composite component according to claim 1, characterized in that one or more workpieces of the composite component in the area ( 13 ) of the connection point ( 6 ) have openings or recesses which are penetrated by the thermoplastic material and form a positive connection of the workpieces. 3. Plastic composite component according to claim 1 or 2, characterized in that one of the workpieces ( 1 ) consists of the same thermoplastic material as the connection point ( 6 ). 4. Plastic composite component according to one of claims 1 to 3, characterized in that one of the workpieces ( 1 ) consists of an elastomer, in particular a thermoplastic elastomer. 5. Plastic composite component according to claim 4, characterized in that the Elastomer is a thermoplastic polyolefin. 6. Plastic composite component according to one of claims 1 to 5, characterized in that one of the workpieces ( 2 ) for shielding electromagnetic radiation consists of a metal which is connected to non-metallic workpieces ( 1 ). 7. Plastic composite component according to one of claims 1 to 6, characterized characterized in that the thermoplastic is selected from the Series: polyamide, polyester, polyolefin, styrene copolymer, polycarbonate, Polypropylene oxide, polyphenylene sulfide, polyimide, PSO or PEEK or possible mixtures of the polymers. 8. Use of the plastic composite component according to one of claims 1 to 7 as a construction element for machines and vehicles, in particular Motor vehicles, for electronic items, household items or building supplies.