WO2001038063A1 - Plastic composite unit - Google Patents

Abstract

The invention relates to a plastic composite unit, which is comprised of at least two flat workpieces made of different materials, e.g. of metal and plastic, and of different metals or plastics. The workpieces are interconnected in the edge area thereof, whereby the connection consists of a thermoplastic which is formed thereon.

Description

Plastic composite component

The invention relates to a plastic composite component which consists of at least two flat workpieces made of different materials, e.g. Made of metal and plastic, different metals or different plastics, which are connected to each other in their edge area, characterized in that the connections of the workpieces consist of molded thermoplastic material.

The form-fitting combination of flat components made of different materials is achieved by forming a thermoplastic material.

The composite component fulfills different technical functions in different areas. It connects e.g. high-strength, temperature-resistant and KTL-compatible components with tailor-made workpieces in functional zones.

Composite components or semi-finished products used in practice consist of e.g. areal connections, where e.g. two metal sheets are connected to a sandwich structure with the aid of an intermediate plastic or plastic foam (cf. EP 489 320 AI, EP 285 974 AI and EP 547 664 A2). There are also processes for the production of composite panels with external sheets and internal rib structure (see EP 775 573 A2). There is also a method for connecting sheet metal by a combination of presses and injection molding in one tool (EP 721 831 AI). In addition, plastic / metal composite components are known in which metal sheets are supported by rib structures (EP 370 342 A3).

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

However, certain special applications require e.g. a plate that different technical characteristics have to be fulfilled at different points on the plate. This can mean that an insulation function is required on one half of the plate and that the other half of the same component should only be used to connect to other separate components or structural elements or to close openings. In this case e.g. If conventional composite panels are used, the component as a whole is overdetermined in terms of its functions and therefore too difficult or too complex to manufacture.

The invention is therefore based on the object of providing a composite component of the type mentioned at the outset which connects the particular acoustic, mechanical, optical or other material properties required in the different areas of the component to the particular functions of the component which are to be performed.

This object is achieved according to the invention in that a component is created which consists of at least two different areas which are in different areas

Are made of materials, which are positively connected to each other by forming a thermoplastic.

The invention relates to a plastic composite component consisting of at least two flat workpieces made of different materials, in particular made of different metals, different plastics, or metal and plastic parts which are connected to one another in their edge area, characterized in that the connection point is made of molded, there is in particular molded thermoplastic and in particular at least one workpiece in the area of the connection point is penetrated by the thermoplastic or is positively enclosed. Suitable high-strength metal materials are steel, aluminum, magnesium. The workpieces can also consist of ceramic, thermosets or plastic composite materials.

As thermoplastic, both as material for the workpieces and for the connection point, there are unreinforced or reinforced, optionally filled plastics such as polyamide, in particular polyamide-6, polyamide-6.6, polyamide-12, polyamide-11 or polyester, in particular polyethylene terephthalate, polybutylene. terephthalate, or polyolefins, in particular polypropylene, styrene copolymers, in particular SAN resin or ABS, or polycarbonate, polypropylene oxide, polypropylene sulfide, polyimide, PSO or PEEK or from possible mixtures of the plastics mentioned.

The composite component is a predominantly flat hybrid component that can also contain linear or punctiform functional elements. Defined joining areas are preferably provided at potential connection points to other components, which can be designed to be variable in terms of shape, position and size, and also with regard to the material.

In a preferred form of the composite component, one or more workpieces of the composite component have openings or recesses in the region of the connection point, which are penetrated by molded thermoplastic material and form a positive connection of the workpieces.

A particularly preferred embodiment of the composite component is characterized in that one of the workpieces consists of the same thermoplastic material as the point of use.

In a preferred embodiment, one of the workpieces consists of an elastomer, in particular a thermoplastic elastomer. Such components are accessible, for example, by the basically known two-component injection molding technique.

The elastomers are preferably thermoplastic polyolefin and thermoplastic polyurethane.

If necessary, in a preferred embodiment of the invention, one of the workpieces of the component for shielding electromagnetic radiation is produced from a metal which is connected to further non-metallic workpieces.

Workpieces of the composite component according to the invention, which are to be connected to a construction or other components different from the composite component, can be freely selected in accordance with the suitable joining or connecting technique.

If the plastic composite component according to the invention e.g. welded to a steel frame, the workpiece abutting the frame will be a weldable steel sheet.

In this way it becomes possible to fasten the entire plastic composite component according to the invention at different locations with completely different connection techniques to external components or constructions, e.g. by means of metal welding and plastic friction welding.

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

The workpieces are connected to one another in the form of sheets, sheets, plates, profiles (open or closed profiles) or hollow chambers. The type of material, number and shape of the workpieces can be varied as required. In a pre- Drawn design, flat workpieces, such as metal sheets and plastic plates, are positively connected to each other at their edges. For this purpose, rivet heads made of thermoplastics are formed in the area of openings on top of one another, which enable a firm connection to the high-strength workpiece (eg sheet metal).

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

There is also the possibility of creating a composite component that consists of several directly connected high-strength workpieces that are also secured by means of plastic rivet connections, whereby the plastic component also e.g. in the form of a molded plastic plate, takes on other tasks.

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 overall component is improved or the assembly of the component is facilitated. In addition, by designing the flexible workpieces as a film hinge, the component can be made partially movable.

At isolated points of a component, shielding against electromagnetic radiation can be achieved by using metal sheets as the workpiece, which are coated with non-conductive materials e.g. thermoplastics or other non-metallic workpieces are connected.

Any connection points of the component according to the invention to other components or constructions can be made by the positive connection of the individual Workpieces in all known materials. The joining process is therefore freely selectable.

When choosing a high-temperature-resistant plastic (polyamide, polybutylene terephthalate, polyethylene terephthalate, polypropylene oxide, PSO, polyphenylene sulfide, polyimide, PEEK or mixtures of these materials in non-reinforced 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. Plastic and high-strength component (metal workpiece):

1. Form-fitting connection of plastic workpiece and high-strength workpiece through material forming.

In this manufacturing process, the connection can be achieved both by injection molding and by plastic riveting using previously formed connecting elements. In both cases, this becomes high-strength

Provide the workpiece with openings in the area of the connection point (e.g. sheet metal with holes in the edge area) through which thermoplastic material penetrates and thus a positive connection is achieved.

When connecting by injection molding, for example, a metal sheet is first placed in an injection mold. The injection molding process creates a less solid workpiece in the form of a plate, for example, and also achieves the connection to the metal sheet. Since the plastic material is poured into the injection molding tool in liquid form, it can flow through the openings in the metal sheet and rivet on the back of the metal sheet. form heads. 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.

In a similar manner, a connection of a less rigid workpiece to a high-strength workpiece can also be achieved when using plastic riveting. The thermoplastic is first injected separately in an injection mold without a metal sheet, but with molded connecting pins. Then one or more metal sheets are placed on the plastic part, the connecting pins projecting through prepared openings in the metal sheet or sheets. The connecting pins are then shaped 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 by means of plug-in or snap connections. With this

First, a plastic workpiece is produced, which is equipped with the necessary plug-in or snap elements. For this, e.g. an injection molded plastic part with molded pins are used, which are inserted into prepared openings of the high-strength workpiece.

Other options for connecting the workpieces are to use different combinations of the methods mentioned. Accordingly, there is the possibility of form locking between the high-strength workpieces by fitting congruent beads in both parts. With an additional congruent breakthrough in both high-strength workpieces a rivet connection, for example by reshaping connecting pins formed on the plastic part, are attached.

The advantages achievable with the invention can be summarized as follows:

The composite component enables a composite surface made up of workpieces with materials that can be varied as required.

There is the possibility of designing composite components with partially different stress types and heights.

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

The invention further enables the free choice of the joining process for connection to other components and construction elements as well as the production of a composite surface from different materials in one process step.

In a corresponding design, the composite components according to the invention are widely used as construction elements for machines, vehicles and components of all types, in particular for motor vehicles, for electronic articles, household articles and for building requirements.

Particularly suitable applications of the composite component are structural parts for motor vehicles, doors, bumpers, beams, front and rear parts for cars, door sill support frames and decorative elements which combine increased strength with other 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.

2 shows the connection of two high-strength workpieces via a medium-strength workpiece made of plastic;

3 shows the connection of a plurality of metal sheets via a workpiece made of thermoplastic polyurethane;

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

5 shows the cross section through a composite of three metal sheets with a fold.

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 is supported to accommodate larger surface loads, the plate 1 by two underlying U-profiles 5 made of aluminum and an integrated rib structure 4 made of the same material as the plate 1. 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 a correspondingly shaped injection molding tool and then injecting the thermoplastic component, with which the plate 1, the rib structure 4 and the form-fitting 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 to the

Plate 1 placed so that the pins of plate 1 fit into the prepared openings of components 2, 3 and 5. The spigots are then formed into positive connections 6 by means of ultrasonic welding. Example 2

Cross section through a composite of three metal sheets: FIG. 2

2 shows how different high-strength workpieces (metal sheets) can be connected directly to one another. The metal sheets 2 are provided with a fold 11 in the edge area, so that the metal sheets 2 and 10 are positively connected to one another. By enclosing these connection points with the thermoplastic component 15 by means of injection molding, the positive connection of the various metal sheets is ensured.

Example 3

Cross section through a flexible composite of metal sheets 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. A further metal sheet 12 is connected to the composite in a different plane via a thermoplastic element 16 made of rigid plastic material. The elastic plate 9 and the thermoplastic element 16 can be molded in one step by means of two-component injection molding of metal sheets 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. Workpieces 2 and 7 are placed in an injection mold and partially overmolded with a thermoplastic in their edge area. At the same time connecting pins are formed, which in a subsequent

Operation after placing the tunnel cover 8 by means of ultrasonic welding to be riveted 6.

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

Example 5

Cross section through a composite of three metal sheets (Fig. 5)

5 shows how different high-strength workpieces (metal sheets) can be connected directly to one another. The metal sheets 52 and 10 are provided with a fold 51 in the edge region, so that the metal sheets 52 and 10 are positively connected to one another. By enclosing this

Joints with the thermoplastic component 55 by means of injection molding, the positive connection of the various metal sheets 52 and 10 is secured.

Claims

claims 1. Plastic composite component consisting of at least two flat workpieces (1) and (2) made of different material, in particular different metal, different plastic or metal and Plastic parts which are connected to one another 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 region of the connection point (6) is penetrated by the thermoplastic 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 or thermoplastic polyurethane. 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 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.