CN109720415B - Method for manufacturing an improved hybrid structural component for a motor vehicle and corresponding hybrid structural component - Google Patents
Method for manufacturing an improved hybrid structural component for a motor vehicle and corresponding hybrid structural component Download PDFInfo
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- CN109720415B CN109720415B CN201711161554.XA CN201711161554A CN109720415B CN 109720415 B CN109720415 B CN 109720415B CN 201711161554 A CN201711161554 A CN 201711161554A CN 109720415 B CN109720415 B CN 109720415B
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Abstract
The invention relates to a method for producing a hybrid structural component (1) for a motor vehicle, characterized in that it comprises the following steps: during these steps, -shaping the sheet of metal material to form the metal part (2); -joining one or more reinforcing tapes (3) formed by continuous fibres wrapped in a polymer matrix to a sheet (4) of composite material formed by fibres impregnated in a thermoplastic polymer matrix, so as to produce a composite reinforcing sheet (5); -arranging the metal component (2) and the composite reinforcement sheet (5) into a mould (10), wherein the composite reinforcement sheet (5) is arranged such that the composite material sheet (4) is in contact with one of the faces (23, 24) of the metal component (2); and-closing the mould to pass through the stamping forming and to make the composite reinforcement sheet (5) adhere to the face of the metal component (2).
Description
Technical Field
The subject of the invention is a method for manufacturing a hybrid structural component of a motor vehicle, in which said component is formed by assembly of a plurality of different materials, such as metal elements, polymeric materials and reinforcing fibres, with the aim of imparting to the component specific mechanical characteristics.
Background
In fact, certain structural elements of motor vehicles are particularly stressed when subjected to impacts. These elements must be able to provide the rigidity and strength necessary to withstand these stresses, absorb a portion of the energy to maintain vehicle integrity, and ensure passenger safety. Such a structural component is for example a center pillar, a longitudinal outer rail, a roof rail, an impact beam or the like or (possibly) any other structural element of the vehicle.
These structural elements must also be strong enough to locally support various mechanical functions. As an example, a motor vehicle center pillar that is highly stressed in the event of a lateral impact must also simultaneously ensure the support of the rear door by the hinges and the stabilization of the front door by the front door closing system.
The hybrid structural component is also capable of significant weight savings of about 30% over conventional metal components at the same mechanical strength while improving the cushioning characteristics.
Patent publication EP 1550604 proposes a method for producing a hybrid structural component, in which a metallic structural element is shaped, which is coated beforehand with a surface coating that can be activated when exposed to heat. The thermoplastic material forming the ribs is then added by overmolding to the face of the metallic structural element containing the surface covering. However, the hybrid structural component lacks impact strength because it does not include reinforcing means comprising fibers.
The case of such hybrid structures is also known: the hybrid structure comprises a composite material and a reinforcing means formed by a layer of fibres impregnated in a polymer matrix and constituting a reinforcing tape. The fibrous layer is typically formed of unidirectional fibers, possibly including one or more additional layers of woven fibers. After the application of the intermediate layer of joining material to the metal element, the composite layer is preferably formed directly in the preformed metal structural element by hot stamping. The reinforcing strip is then arranged on all or part of the face of the metallic structural element carrying the composite layer. The reinforcing elements in the form of ribs are then produced by overmoulding of a thermoplastic or thermosetting polymer material, preferably in the same mould as that used for the stamping step. The polymeric material covers the reinforcing tape and a portion of the metallic structural element left free by the reinforcing tape. The method can obtain high quality parts. However, to avoid movement of the reinforcing tape when this operation is performed by injection during overmolding of the polymeric material, numerous precautions must be taken. Especially when the reinforcing tape only partially covers the surface of the metal structure.
Disclosure of Invention
The aim of the present invention is to propose, instead of the above-mentioned method, a method for manufacturing a hybrid structural component which allows to reduce the manufacturing costs of the hybrid structure while ensuring a good accuracy of the positioning of the reinforcing tapes with the composite sheet.
The method for manufacturing a hybrid structural component for a motor vehicle according to the invention comprises the following steps during which:
-a step a: a sheet of metal material is formed to form a metal part,
-a step b: bonding one or more reinforcing tapes formed of continuous fibers encased in a polymer matrix with a composite sheet formed of fibers impregnated in a thermoplastic polymer matrix to produce a composite reinforcing sheet,
-a step c: arranging the metal part and the composite reinforcement sheet into a mould, wherein the composite reinforcement sheet is arranged such that the composite material sheet is in contact with one of the faces of the metal part,
-a step d: the mold is closed to pass through the press forming and the composite reinforcement sheet is attached to the face of the metal part.
The reinforcing tape is positioned on the composite sheet and is pre-joined to the composite sheet by any means to form the composite reinforcing sheet prior to its introduction into the mold. The relative positions of these different sheets are thus accurate. Furthermore, it has been verified experimentally that the maintenance of the position of the composite reinforcement sheet in the mould during the stamping step (during which the composite reinforcement sheet deforms) does not cause problems, in particular when the composite reinforcement sheet covers a large area.
The method according to the invention may also comprise the following features, either alone or in combination:
-at step b, joining the reinforcing tape with the composite sheet by adhering the reinforcing tape and the composite sheet to each other.
-the composite sheet and the polymer matrix of the reinforcing tapes are compatible thermoplastic materials and, during step b, the surface temperature of said composite sheet is raised to close to the melting temperature of the thermoplastic material and the surface temperature of the reinforcing tapes is raised to close to the melting temperature of the polymer matrix encasing the continuous fibers so that the composite sheet and the reinforcing tapes are connected by welding.
-at step b, the reinforcement tapes are joined to the composite sheet by mechanical means such as needles, staples or by local deformation of the composite sheet.
-during step c, raising the temperature of the composite reinforcement sheet above the glass transition temperature Tg and close to the melting temperature of the polymer matrix of the composite sheet.
-during step c, raising the temperature of the metal part to a temperature close to that of the mould, wherein the temperature of the mould is in the range of 70 ℃ to 160 ℃, preferably in the range of 80 ℃ to 140 ℃.
The reinforcing tapes comprise unidirectional continuous fibers.
The fibres of the reinforcing tape are woven.
The reinforcing belt portions are either completely superposed on one another.
The composite sheet comprises woven continuous fibers.
-the composite sheet comprises non-woven interlaced staple fibres.
-said fibres are selected from glass fibres, carbon fibres, basalt fibres, metal fibres or aramid fibres.
At the end of step d, a step e is carried out during which the thermoplastic or thermosetting material is overmoulded by injection or by hot pressing.
-a thermoplastic or thermoset material is overmoulded on the same face of the metal part on which the composite reinforcement sheet is arranged.
-a thermoplastic or thermoset material is overmoulded on the face of the component opposite to the face on which the composite reinforcement sheet is arranged.
-the overmolded thermoplastic or thermoset material is a material filled with cut fibers.
-a thermoplastic or thermosetting material overmoulded on one of the faces of the metal part forming a reinforcing rib.
-covering the face of the metal part intended to receive the composite reinforcement sheet and possibly the face intended to receive the layer of thermoplastic or thermosetting material with an adhesive layer before carrying out step c.
-before carrying out step a, the metal sheet is subjected to a mechanical treatment to produce a surface roughness on its face intended to receive the composite reinforcement sheet or the layer of thermoplastic or thermosetting material.
The mould comprises needles extending through the composite reinforcement sheet advantageously positioned to hold the composite reinforcement sheet in position during step c.
The invention also relates to a hybrid structural component for motor vehicles, which can be obtained by implementing a method according to at least one of the above features, characterized in that it comprises a shaped metal part, on one face of which there is attached a sheet of composite material formed of fibres impregnated in a thermoplastic polymer matrix, on which sheet of composite material there is superimposed one or more reinforcing tapes formed of continuous fibres wrapped in a polymer matrix.
Drawings
The invention will be better understood on reading the attached drawings, which are provided by way of example and in no way limiting, in which:
FIG. 1 shows a schematic view of a hybrid structure of a motor vehicle, such as a center pillar;
FIG. 2 is a schematic cross-sectional view of the hybrid structure at A-A, according to a first embodiment of the present invention;
FIG. 3 is a schematic cross-sectional view of the metal part obtained at step a;
FIG. 4 is a schematic cross-sectional view of a reinforcing tape;
FIG. 5 is a schematic cross-sectional view of a composite sheet;
FIG. 6 is a schematic cross-sectional view of the composite reinforcement sheet obtained at step b;
FIGS. 7, 8 and 9 are schematic illustrations of steps c and d for manufacturing a hybrid structural component according to a first embodiment of the present invention;
FIG. 10 is a schematic cross-sectional view of a hybrid structure (reminder: same as hybrid structure of FIG. 2);
11, 12 and 13 are schematic illustrations of steps c and d for manufacturing a hybrid structural component according to a second embodiment of the present invention;
fig. 14 is a schematic cross-sectional view along a-a of a hybrid structure obtained according to a second embodiment of the invention;
figure 15 is a schematic view of step e for manufacturing a hybrid structural component according to a third embodiment of the present invention;
fig. 16 is a schematic cross-sectional view along B-B of a hybrid structure obtained according to a third embodiment of the invention;
fig. 17, 18 and 19 are cross-sectional views of a composite reinforcement sheet, a metal part and an assembly thereof according to a fourth embodiment of the present invention.
Detailed Description
The hybrid structural component 1 shown in figure 1 is a motor vehicle center pillar and comprises a profiled metal component 2 over-moulded with a layer 6 of thermoplastic or thermosetting material. The ribs 61 made of thermoplastic or thermosetting material are locally arranged to reinforce the structure of the metal part 2 by increasing the overall inertia of the hybrid structure. When the metal part 2 has a cavity (for example in the shape of a U), a rib 61 made of thermoplastic or thermosetting material is advantageously arranged inside the cavity to limit the opening or closing of the cavity or the two wings of the U to a large extent under the effect of the impact. The ribs 61 may have a longitudinal or transverse orientation or form a cross as shown in fig. 1. The reinforcing sheet is not visible in fig. 1.
Figure 2 shows a cross-section along a-a of a hybrid structural component formed by the assembly of a metal component 2, a composite sheet 4 and a reinforcing strip 3.
The forming of the metal sheet used for manufacturing the metal part 2 at step a (shown in fig. 3) is preferably carried out by cold or hot stamping. The metal sheet is in the form of a sheet having a thickness in the range of 0.1mm to 1.5mm, more typically in the range of 0.5mm to 1 mm. The metal sheet can be made indiscriminately of aluminium, magnesium, titanium or of one or more alloys of these metals. More often, an iron-based alloy, for example steel or stainless steel, preferably a cold-drawable metallic material, is selected.
Step b consists in assembling by superposing a reinforcing tape 3 (as schematically shown in figure 4) with a composite sheet 4 (as schematically shown in figure 5) to form a composite reinforcing sheet 5 as shown in figure 6.
The continuous fibers of the reinforcing tapes 3 are encased in a polymer matrix. The fibers are selected from the most common reinforcing fibers, such as glass fibers, carbon fibers, basalt fibers, metal fibers, aramid fibers (les fibers). These fibers may be single strand fibers or more generally a multi-stranded twisted wire to improve the mechanical strength of the part.
These continuous fibers may all be oriented in the same direction, so called unidirectional reinforcing fibers, which are parallel to each other and generally aligned with respect to the main direction of the hybrid structural component 1 to be manufactured. A reinforcing tape 3 comprising woven continuous fibers may also be used.
The polymer material that wraps the reinforcing tapes 3 or the composite sheet 4 is preferably a thermoplastic material and can be chosen from aliphatic polyamides (PA for short), polyphthalamide (PPA), polybutylene terephthalate (PBT for short), polyethylene terephthalate (PET for short), Polycarbonate (PC), even polypropylene (PP) and mixtures thereof. By way of example, polyamide 66(PA66) or polyamide 6(PA6) may be used.
The number, position and orientation of the continuous fibers of the reinforcing strips 3 are chosen according to the positioning of the forces to which the hybrid component is subjected when it is impacted, and are the result of calculations during the research phase according to the strength of the material implemented. The unidirectional continuous fibers forming each layer of the reinforcing tape 3 may be oriented in the same direction or at a determined angle to each other. One or more unidirectional continuous fiber layers may also be combined with one or more woven continuous fiber layers, as desired. The reinforcing tape thus assembled may have a thickness of from 3mm to 6 mm.
It is to be noted here that one or more reinforcing strips 3 can be arranged. These reinforcing strips 3 can be completely or partially superposed or even completely separated from one another. It is noted that the reinforcing tapes cover each other over the entire surface thereof or only a part of their respective surface. The reinforcing tape extends over all or a portion of the surface of the hybrid structural component.
The composite sheet 4 comprises fibres impregnated in a thermoplastic polymer matrix. The matrix may have the same or different properties as the polymer matrix in which the fibers of the reinforcing tape are wrapped. The matrix may be achieved by known process methods, such as the RTM process (Resin Transfer Molding), possibly under high pressure, by compaction on a double belt press (e.g. by rolling), by extrusion, or by any other suitable process (e.g. polymerisation stage monomer impregnation method).
Such a composite sheet 4, in addition to its bonding properties with the metal part 2, also imparts a high energy absorption capacity to the final hybrid structural part 1, thereby improving its strength against impacts. In effect, the composite sheet 4 combines a series of failure modes (mode de ruine) as it undergoes high levels of deformation, each absorbing energy.
Advantageously, the composite sheet 4 may comprise one or more layers of woven or non-woven long or short fibres having the same or different properties as the fibres constituting the reinforcing tape, here likewise selected from glass, carbon, basalt, metal or aramid fibres. The thermoplastic polymer that encases the fibers of the composite sheet is also selected from the aforementioned polymeric materials and is selected for its ability to adhere to the surface of the metal part 2. The thermoplastic polymer material must also be compatible with the polymer material forming the reinforcing strips 3, so that at the end of step b, the material of the sheets is highly adherent to each other.
The manufacture of the composite reinforcement sheet 5 at step b is achieved by superimposing the reinforcement tapes 3 on the composite material sheet 4. The position of the reinforcing sheet may be appropriately adjusted in consideration of the deformation of the composite reinforcing sheet at the time of the punching or hot pressing operation. This operation has a high accuracy, especially when the operation is performed by a robot. Furthermore, all precautions are taken to maintain these relative positions throughout the steps following the method, so that the position of the pieces on the mixing member is also very precise.
Preferably so that the reinforcing strips 3 can adhere to the composite sheet 4. This procedure may be accomplished by a heating operation that warms the face of the composite sheet 4 that receives the reinforcing tape 3 to near the melting temperature of its thermoplastic material and warms the surface of the reinforcing tape 3 to near the melting temperature of the polymer matrix that encases the continuous fibers, such that the face of the composite sheet and the face of the reinforcing tape that are disposed face-to-face are bonded by welding. This operation is particularly suitable for using a mirror welding apparatus that can locally heat the contact portion of each sheet.
It is also possible to join the reinforcing strips 3 to the composite material sheet 4 by local deformation by applying local pressure at suitably selected compression points. It is even conceivable to arrange local connections such as nails or rivets.
Another alternative consists in using needles suitably arranged on the clamping and loading robot and in the mould during steps c and d, which penetrate the various layers formed by the reinforcing strips 3 and the composite sheet 4.
At the end of step b, a composite reinforcement sheet 5 is obtained, formed by the assembly of reinforcement strips 3 and composite sheet 4.
Fig. 7 shows a step c during which the composite reinforcement sheet 5 is introduced into the mould 10, preferably and for precision reasons, by means of a robot (not shown).
The mold 10 comprises a fixed part 102 and a movable part 101 movable with respect to the fixed part 102.
As an example, the metal member 2 is arranged on the fixing portion 102.
Before it is introduced into the mould, the composite reinforcement sheet 5 is heated to a temperature sufficient to cause it to soften and adhere to the metal part.
When the material of the composite reinforcing sheet is of the thermoplastic type, the temperature of said sheet 5 is raised in an oven above the glass transition temperature Tg and close to the melting temperature, so that the layer is highly softened.
When the material of the composite reinforcement sheet 5 is of the thermosetting type, the sheet may be introduced into the mould, possibly at ambient temperature, or preferably heated to a temperature in the range between 40 ℃ and 80 ℃.
Likewise, the temperature of the metal part 2 may be raised to a temperature close to that of the mold.
The composite reinforcement sheet 5 is then arranged precisely above the fixing portion 102 during step c. As previously described, the surface of the mold 101 may include needles 101b for penetrating the thickness of the composite reinforcement sheet 5 to maintain the relative positions of the reinforcement tape 3 and the composite sheet 4.
Note also that the mold has a slight depression 101a in a portion 101 of the mold for contact with the reinforcing tape at a lift height formed by the reinforcing tape 3 on the surface of the composite reinforcing sheet 5. This particular recess, because of its profile matching the shape of the excess thickness, makes it easier to position the composite reinforcement sheet 5 and to maintain its position during step d.
Fig. 8 and 9 show the movement of the mould during step d. The movable part 101 is lowered to deform the composite reinforcement sheet 5 (see figure 9) until the sheet comes into contact with the metal part 2 on which it is highly pressed.
As an example, the pressure applied during the stamping or hot pressing step may be from 80 to 300bar, preferably from 100 to 200 bar. During the application of the pressure, the mould may possibly be kept at a temperature in the range of 70 ℃ to 160 ℃, preferably in the range of 80 ℃ to 140 ℃.
In order to be able to better adhere the composite reinforcement 5 to the surface of the metal component 2 by deformation, care is taken to minimize irregularities in the contour of the metal component.
At the end of step d, the part is removed from the mould to obtain the part of fig. 2 (this part is shown again in fig. 10). According to this first embodiment of the present invention, the composite reinforcement sheet 5 is arranged on the concave surface 23 side of the metal member.
Fig. 11, 12 and 13 show a second embodiment of the invention, in which a composite reinforcement sheet 5 is arranged on the convex surface 24 side of the metal member 2.
At step c, after the metal member 2 is arranged on the fixed portion 102 of the mold (the convex surface of the metal member is directed toward the movable portion of the mold), as shown in fig. 11, the composite reinforcing sheet 5 is introduced in such a manner that the face formed by the composite material sheet 4 is located on the metal member side.
At step d, with reference to fig. 12 and 13, the mould is closed so that the composite reinforcement sheet 5 is stamped on the convex surface 24 of the metal part 2.
The hybrid structural component obtained at the end of step d is shown in fig. 14.
Fig. 15 and 16 show a third embodiment of the invention, in which, at the end of step d, a step e is carried out during which the thermoplastic or thermosetting material 6 is overmoulded by injection or hot pressing to form the reinforcing ribs 61. These reinforcing ribs are generally located on the concave surface 23 side of the metal part 2.
In conjunction with the foregoing, the thermoplastic or thermoset material may be overmolded onto face 23 (the same face on which composite reinforcement sheet 5 is disposed) or face 24 opposite it.
At step e, the overmoulding of the layer 6 of thermoplastic material is preferably carried out by injection in the same mould as step d of the method, during which the composite reinforcement sheet 5 has been stamped on the metal part, has been carried out. The mould 10 should thus be able to free up space for being occupied by the thermoplastic or thermosetting material 6, for example by providing an extractable drawer. When the material forming the layer 6 is a thermosetting type material, a method by means of hot pressing is preferably chosen.
In order to reduce heat consumption, the overmoulding of the layer 6 is preferably carried out immediately at the end of step d, while the composite reinforcement sheet and the metal part are still at a temperature sufficient to allow bonding by welding between the composite reinforcement sheet 5 and the overmoulded layer 6.
A thermoplastic or thermoset overmold layer 6 covers all or a portion of the surface of the metal component 2.
Advantageously, the thermoplastic or thermosetting material used for the overmould layer 6 may comprise short fibres arranged randomly to obtain a higher strength reinforcing component. The fibers are likewise selected here from glass fibers, carbon fibers, basalt fibers, metal fibers, aramid fibers.
The thermosetting polymeric material may be a polyester, vinyl ester, epoxy, polyurethane resin or mixtures thereof.
Preferably, for the over-molded layer, a polymer matrix is chosen that is the same as or compatible with the material forming the composite sheet 4 and the reinforcement sheet 3, in that these constituent components are intended to be assembled to form a single mechanically strong part.
More preferably, for the polymer matrix used to realize the layer 6 and the reinforcing ribs 61, the polymer matrix that wraps the fibers of the reinforcing tapes 3, and the polymer matrix of the composite sheet 4, compatible thermoplastic materials are chosen so that said polymer matrices of these three components are joined to each other by welding. By way of example, when the material of the composite reinforcement sheet is of the polyamide PA type (PA6, PA66, PA12, PA11), a polyamide type material (PA6, PA66, PA12, PA11) can be chosen for the injection layer.
In contrast, when the composite reinforcement sheet 5 is of the thermosetting type (by way of example: epoxy resin), the injection layer 6 can be realized optionally by means of a material of the polyamide PA type (PA6, PA66, PA12, PA 11). And when the compatibility of the materials forming the composite sheet 5 and the overmoulded layer 6 is low, it can be advantageously considered to carry out a pre-treatment of the surface by a mechanical type treatment (scraping, grinding, laser), by plasma activation or by adding a compatible layer in the form of an adhesive sheet which can be pressed against the thermosetting layer D during step D, before carrying out the injection or hot-pressing of the overmoulded layer 6.
Fig. 18 shows a fourth embodiment of the invention, in which, before the metal part is introduced into the mould during step c, the metal part is provided with an adhesive layer on the face 23 or 24 for receiving the composite reinforcing sheet 5 and, if necessary, on the face 23 for receiving the overmoulded layer 6, with the aim of enhancing the adhesion between the metal part and the polymer matrix of the reinforcing element 3, 4, 6. The adhesive material 7 may be of the "thermally activatable" type, the adhesion of which to the polymer matrix takes place under predetermined temperature conditions. This activation of the bonding material 7 may advantageously be achieved at the molding temperature and pressure of the material forming the overmold layer 6. This bonding material 7 is in the form of a single layer of polymeric material that is chemically compatible with the material forming the composite reinforcement sheet 5 and/or the overmolded layer 6.
The adhesive material 7 can be any material known by the english name "hot-melt", and can be chosen from materials based on copolyesters or on copolyamides or from elastomeric thermoplastic materials based on polyolefins. As a non-limiting example, these materials are under the name EMS
CE20、EMS
CT10、Nolax
391 to market.
The bonding material 7 may also be a material capable of cross-linking (resorculer). For this type of material, subsequent softening is not feasible, especially in the case of exposure to a predetermined temperature for a given length of time (advantageously during the injection molding of the overmoulded layer or the electrophoresis and painting cycles on the production line). This has the advantage of at least partially joining the overmold 6 to the metal part 2 at such a strength level: this level of strength can pass all heating steps of the subsequent manufacturing chain of the motor vehicle manufacturer.
The cross-linkable adhesive material may be chosen from materials based on copolyamides, possibly including isocyanates (isocyanate), epoxies and even polyolefins. As a non-limiting example, these materials are by name
X1333-P1、
HCM 555、Lohmann
Tesa
And (4) selling.
The arrangement of this layer 7 of bonding material is generally carried out on the sheet material used for forming the metal part 2, preferably before step a, by simple spraying or rolling (rolling) of a layer of very small thickness.
The implementation of steps a, b, c, d and possibly e of the method is carried out in the same way as described above.
As an illustration, the composite reinforcing sheet 5 of fig. 17 and the hybrid component of fig. 19 (formed by the assembly of the sheet of fig. 17 with the metal component of fig. 18) comprise two reinforcing strips 3.
An embodiment variant (not shown) of the fourth embodiment of the invention, which is able to reinforce the adhesion of the composite reinforcement sheet 5 and/or of the overmould layer 6 to the metal part 2, consists in mechanically treating the surface of the metal part 2.
For this purpose, a surface roughness is achieved before step a on the sheet metal material used to form the metal component 2 or on the surface of the metal component 2 itself. These surface roughnesses may be obtained by laser treatment to create surface texture, by grinding, or by any other means that can produce surface variations.
Of course, it is entirely possible to combine two embodiments of the invention or to implement these embodiments simultaneously.
Finally, the invention relates to a hybrid structural component 1 for a motor vehicle, which can be obtained by implementing a method according to the aforementioned characteristics. The hybrid structural component comprises a profiled metal part 2 to one face 23, 24 of which a sheet 4 of composite material formed from fibres impregnated in a thermoplastic or thermosetting polymer matrix is adhered. A reinforcing tape 3 formed of continuous fibres encased in a polymer matrix is superimposed on the face of the composite sheet 4 opposite to the face to which the metal part 2 is adhered.
Term(s) for
1 hybrid structural component
2 Metal part
23 face of metal part comprising reinforcing ribs
24 face of metal part opposite to face including reinforcing rib
3 reinforcing tape formed of continuous fibers encased in a polymer matrix
4 composite sheet formed of fibres impregnated in a thermoplastic polymer matrix
5 composite reinforcing sheet
6 overmold formed from thermoplastic or thermoset material
61 reinforcing ribs made of thermoplastic or thermosetting material
7 tie layer formed of a polymer material
10 mould
101 upper part of the mould
101a recess
102b holding needle
102 lower part of the mould
103 injection channel
Claims (18)
1. A method for manufacturing a hybrid structural component (1) for a motor vehicle, characterized in that it comprises the following steps, during which:
step a: shaping a sheet of metal material to form a metal part (2),
step b: bonding one or more reinforcing tapes (3) formed of continuous fibres encased in a polymer matrix to a sheet (4) of composite material formed of fibres impregnated in a thermoplastic polymer matrix to produce a composite reinforcing sheet (5),
step c: arranging the metal component (2) and the composite reinforcement sheet (5) into a mould (10), wherein the composite reinforcement sheet (5) is arranged such that the composite material sheet (4) is in contact with one of the faces (23, 24) of the metal component (2),
Step d: closing the mold by press forming and attaching the composite reinforcing sheet (5) to the face of the metal member (2),
wherein needles (101b) suitably arranged on the clamping and loading robot and in the mould (10) are used during steps c and d, said needles penetrating the various layers formed by the reinforcing strips (3) and the composite sheet (4).
2. Manufacturing method according to claim 1, wherein during step c the temperature of the composite reinforcement sheet (5) is raised above the glass transition temperature Tg and close to the melting temperature of the polymer matrix of the composite sheet (4).
3. Manufacturing method according to claim 1 or 2, wherein during step c the temperature of the metal part (2) is raised to a temperature close to the temperature of the mould, wherein the temperature of the mould is in the range of 70 ℃ to 160 ℃.
4. The manufacturing method of claim 3, wherein the temperature of the mold is in the range of 80 ℃ to 140 ℃.
5. Manufacturing method according to claim 1, wherein the reinforcing tapes (3) comprise unidirectional continuous fibres.
6. The method of manufacturing of claim 5, wherein the fibers of the reinforcing tape are woven.
7. Manufacturing method according to claim 1, wherein a plurality of said reinforcing tapes (3) are partially or completely superimposed on one another.
8. Manufacturing method according to claim 1, wherein the composite material sheet (4) comprises woven continuous fibres.
9. A manufacturing method according to claim 1, wherein the composite sheet (4) comprises non-woven interwoven short fibers.
10. The manufacturing method according to any one of claims 6 to 9, wherein the fiber is selected from a glass fiber, a carbon fiber, a basalt fiber, a metal fiber, or an aramid fiber.
11. Manufacturing method according to claim 1 or 2, wherein, at the end of said step d, a step e is carried out during which the thermoplastic or thermosetting material (6) is overmoulded by injection or hot-pressing.
12. Manufacturing method according to claim 11, wherein the thermoplastic or thermosetting material (6) is overmoulded on the same face (23) of the metal part (2) as that on which the composite reinforcement sheet (5) is arranged.
13. Manufacturing method according to claim 11, wherein the thermoplastic or thermosetting material (6) is overmoulded on the face (23) of the metal part (2) opposite to the face (24) on which the composite reinforcement sheet (5) is arranged.
14. Manufacturing method according to claim 11, wherein the thermoplastic or thermosetting material (6) that is overmoulded is a material filled with cut fibres.
15. A manufacturing method according to claim 11, wherein the thermoplastic or thermosetting material (6) overmoulded on one (23) of the faces (23,24) of the metal component (2) forms a reinforcing rib (61).
16. Manufacturing method according to claim 1 or 2, wherein, before carrying out step c, the face of the metal component (2) intended to receive the composite reinforcing sheet (5) is covered with an adhesive layer (7).
17. Manufacturing method according to claim 16, wherein, before carrying out step c, the face of the metal component (2) intended to receive the composite reinforcement sheet (5) and the face intended to receive the thermoplastic or thermosetting material (6) are covered with an adhesive layer (7).
18. The manufacturing method according to claim 1 or 2, wherein, before carrying out step a, the sheet of metal material is subjected to a mechanical treatment to produce a surface roughness on its face intended to receive the composite reinforcement sheet or the thermoplastic or thermosetting material.
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