DE102004050666A1 - Composite component for use in cars, aircraft, ships and domestic or electrical equipment, comprises a plastic base part protected from external stress by a metal sheet attached by a rim pressed into the plastic - Google Patents

Abstract

A composite component (I) with a plastic base part (A) and at least one element (B) to protect part (A) at least where there is an external stress, in which the protective element (B) forms a positive (interlocking) and/or non-positive joint with (A). An independent claim is also included for a method for the production of (I) by using a protective element (B) with at least one surface which has a rim with a sharp-edged contour which can be pressed into a plastic structure on (A) to form a joint.

Description

The The present invention relates to a composite component with a body plastic, on which at least in areas of external stress, at least one element for the protection of the body with positive and / or non-positive the main body made of plastic.

Plastic structures are used in vehicle, machine and apparatus construction, as they represent a cost-effective variant for intelligent lightweight solutions. For example, plastic oil pans are characterized by an enormous freedom of design, low production costs and high damping against engine noise. In order to give the structure sufficient rigidity and strength, plastic components are often supplemented with metal elements that are screwed, glued or connected to the plastic via fasteners. Out DE 198 18 590 C2 In addition, a molding of a metal mesh construction with plastic is known, so as to produce a material connection.

Out DE 101 25 559 A1 is a composite component, which has a positive and non-positive plastic / metal compound, and a corresponding joining method for its production known. Here, by moving together joining tools, in each of which a plastic component and a metal component are inserted, these connected to each other at points at which a formed on the metal component Ziehrand penetrates at the connection points in the plastic structure, that a permanent, positive and non-positive connection. The hybrid component produced in this way combines the advantages of the materials plastic and metal. Thus, the hybrid component over known constructions of only one material, inter alia, increased rigidity and strength, a functional integration in the sense of system and module formation and a weight reduction.

From the automotive sector, components made of plastic are known, which are provided as protection against external mechanical stress, for example against stone chipping, with elements of the same material, for example ribs, on their outer surface facing the road surface. In EP 1 041 253 A1 an oil pan is described in which such ribs are arranged with a lower rigidity at least at the bottom of the tub so in the direction of travel that they deform elastically in an impact and the impact energy is dissipated. The material used is a fiberglass-reinforced polyamide, the necessary elasticity of the ribs being set via a suitable material thickness thereof. Depending on the impact force of, for example, spin-on stones, it can lead to splintering of the thin ribs. In addition, the front of the oil pan, which is opposite to the direction of travel and is particularly susceptible to stone chipping, unprotected.

alternative can Plastic constructions of oil pans on their surface facing the road surface, have ribs which as so-called "sacrificial ribs" in the case of rockfall break and thus reduce the impact energy and not forward in the oil pan. This has a negative effect because the overall construction is damaged and another rockfall in the same place not appropriate can be countered.

Of the Invention is based on the object, a composite component, which via a adequate protection against external loads features, as well as an inexpensive, to provide a simple and variable method for its production.

The solution The task is then a composite component with a base body Plastic, at least in areas of an external load at least has an element for the protection of the body, the form and / or non-positively with the main body made of plastic.

The provided composite component combines the advantages of a Material combination such as for components made of plastic materials and metal result. Plastic offers the possibility of producing a inexpensive construction, which is characterized by a large Freedom of design with simultaneous weight reduction distinguishes. The complement of a basic body made of plastic with a protective element e.g. a metal component gives the composite component achieved stability and protection against external stress, mechanical, static or dynamic, chemical, electrical as well as thermal nature. By the hereinafter facilitated advantageous process for the preparation of the composite belonging to the group of the "Post Molding Assembly" methods, i. the bond between basic body Plastic and protective element is after the actual manufacturing process made of plastic component, the greatest possible diversity in the design given the composite component, as in the publication "plastic and metals in solid composite ", Kunststoffe international 11/2002, Volume 92 presented.

The base body made of plastic may be formed, for example, as an injection-molded or deep-drawn molded part, whereby its design according to the field of application and the requirements. Thus, housing for receiving machine or apparatus elements, supports for receiving electrical circuits or covers or elements for receiving process fluids, for example, oil pans or tanks are generally possible. The molded parts can have connection surfaces or connecting pieces, internal graduations. Furthermore, they can be provided to increase the rigidity rigidity with ribs, webs and other functional elements.

At Locations where an external load is attacking and which are protected, for example by a metal component The construction may have elevations which serve as joining surfaces for joining together serve the metal component and on the other hand as a spacer between plastic and sheet metal act and thus a damping of external stress enable.

The with the main body Plastic element to be connected, which serves as protection against external loads at risk Positions is arranged, is preferably made of metal or a metal alloy and suitable for the joining method used. About that In addition, however, other materials, depending on the type of load, possible, such as e.g. Ceramics, thermosets or thermoplastics. These have at least a hole on and are made with a metal fastener or a metal alloy, which is for the joining method used suitable, attached. The protective element is aimed in his Shape and material according to the requirements resulting from its operation and from the shape of the to be protected the body made of plastic. So can Plates, strips, mesh or other molded parts are used.

Around the connection to the base body to be protected Plastic manufacture features the one component to be connected, preferably a metal component, over at least an area, which has a drawing edge. The goat country is one over the area projecting collar, which has a sharp-edged peripheral edge. The drawing edge is preferably obtained by means of a Stamp in a drawing process breakthroughs in the surface of the component expands. Alternatively you can Pulling through welding or soldering on the corresponding surfaces be applied. Depending on the stamp used are very different breakthroughs for example in the form of straight, wavy or angular lines, Rectangles, ovals, triangles, circles or other geometric Figures possible. These breakthroughs produce a substantially perpendicular to the surface of the component Drawing edge, which is suitable under pressure application in a plastic structure penetrate. The peripheral edge of the drawing edge is therefore advantageous sharp-edged. Among other things, it can be rectangular in cross-section, triangular or trapezoidal be educated. Preferably, circular draw edges become one to be joined component surfaces generated. Alternatively you can for attachment of for the joining method unsuitable Materials the pull collar on a third component, a connecting element, which for the joining process is suitable to be generated with this third component the Composite between the protective element and the base body made of plastic manufacture.

The Thickness of the drawing edge can be freely selected in large areas, as long as the plastic structure is not destroyed during assembly and a positive and / or non-positive Connection is generated. The height of the drawing country is also selectable within limits, as long as at the place to be joined sufficient connection is made and the plastic structure not sustainably weakened at the connection point.

The Composite component is preferably assembled in a process by the main body out Plastic in a joining tool is inserted so that the area at the the connection to the protective Component is provided, against which also in a joining tool inserted component with at least one surface with at least one drawing edge can be pressed, so that the edgy Ziehrand in the plastic structure penetrates and connects with this form and / or non-positively. For joining, i. Can compress from the sheet metal working and sheet metal forming known tools can be used, e.g. Pressing, stamping or deep-drawing tools, in which the components are accurately inserted. Furthermore, special Automates with hydraulic or pneumatic cylinders take over the joining. Around Cracks or breaks In the components to avoid, it is necessary that the moldings on the places of compression or in their immediate vicinity directly and flush against the tool.

In The method used may be the plastic body both Ambient temperature as well as lower or elevated temperatures, where the plastic material is still relatively soft.

Based the drawing, the invention is explained in more detail below. Show it:

1 a protective element such as a metal component and a plastic structure in the region of the joint before joining.

2 a section through the region of a joint after joining, in which a protective element such as a metal component and a plastic structure have entered into a positive and / or non-positive connection.

3 a section through the region of a joint after joining, wherein on the plastic structure, a survey is arranged as a connection surface.

4 a section through the region of a joint after joining, wherein a material unsuitable for the joining method by means of a third component whose material is suitable for the joining method, is connected to the plastic structure.

5 an oil pan as a preferred embodiment of the composite component according to the invention.

In the illustration according to 1 Pressing tools of a joining tool are shown in the extended state. The two opposite joining tools, the lower joining tool 11 and the upper joining tool 13 have facing each other impact surfaces 12 respectively. 14 on. Between the separated landing surfaces 12 respectively. 14 of the lower or upper joining tool 11 respectively. 13 are the parts to be joined together of the composite part, namely plastic structure 1 and the protective element 4 , eg a metal sheet.

The protective element 4 For example, the metal body or the metal sheet can by punching or deep drawing with circularly configured breakthroughs 6 be provided. The circular breakthroughs 6 preferably have a diameter in the range of 2 to 12 mm. During the production of breakthroughs, for example by means of pulling arise laterally at the openings 6 pull-collar-like elevations 7 in a sharp-edged peripheral edge 8th leak at the bottom of the breakthrough. The breakthrough 6 becomes essentially symmetrical to its line of symmetry 10 manufactured. At the top 9 of the pull-collar configured deformed area 7 adjusting peripheral edge 8th is preferably formed sharp-edged, to prevent penetration of the peripheral edge 8th in the top 3 the plastic structure 1 to enable.

For the compression of plastic structure 1 and protective element 4 For the sheet metal processing or sheet metal forming suitable presses, stamping or thermoforming machines or similar-acting machine tools, such as hydraulic or pneumatic cylinders can be used. These are usually made with one or more tools 11 respectively. 13 equipped, the contour of the components to be joined together 1 respectively. 4 are exactly adjusted. For optimal introduction of the joining force when compressing the corresponding components, it is essential that the protective element on the one hand and the plastic structure on the other hand at the joints or to the respective immediate environment accurately to the corresponding tool contact surface l2 respectively. 14 issue.

For the protective element Generally speaking, any metal, metal alloy, or others Materials are used. For a direct assembly of protective element and plastic structure, the material must have a sufficient Have hardness, to be pressed into the plastic structure can. A further material requirement results from the protective function, which takes over the preferred metal sheet over the plastic construction. When an external load occurs, for example, by spin-on stones in the case of an oil pan, The metal sheet absorbs the impact energy and builds it up a corresponding deformation without them in the connected Plastic structure is forwarded. Usual sheets have a sufficient Strength and plastic deformation, e.g. sheet metal DC01, ZSTE340 etc. with a thickness preferably from 0.5 mm to 2 mm. serves that with the main body plastic-bonded component as protection against thermal stress, Thus, the following materials are suitable, such as Ceramics, thermosets or thermoplastics with a high melting point. Is the material suitable? not for the preferred joining method, is introduced a third component, a connecting element, which produces the composite at the corresponding connection points.

When body made of plastic come in particular injection-molded or deep-drawn Moldings used. Usually become the basic body plastic of thermoplastic semi-crystalline or amorphous Made of polymers, but also thermosets or mixtures of these Polymer classes are possible.

When Thermoplastic polymers are all thermoplastics known to those skilled in the art into consideration. For example, suitable thermoplastic polymers in the plastic paperback, ed. Saechtling, 25th edition, Hanser-Verlag, Munich, 1992, in particular Chap. 4, and references cited therein, and in the Plastics Handbook, Editors G. Becker and D. Braun, Volumes 1-11, Hanser Verlag, 1966-1996.

The plastic structures may also contain conventional additives and processing aids. Suitable additives and processing aids are, for example, lubricants or mold release agents, rubbers, antioxidants, stabilizers against Light exposure, antistatic agents, flame retardants or fibrous, spherical and powdered fillers or reinforcing agents and other additives or mixtures thereof.

When examples for fibrous, spherical or powdery Filling and reinforcing materials be carbon or glass fibers in the form of glass fabrics, glass mats or glass silk rovings, chopped glass and glass balls called. Especially preferred are glass fibers. The glass fibers used may be made E-, A- or C-glass and are preferably with a sizing, e.g. on epoxy resin, silane, aminosilane or polyurethane basis and a bonding agent based on functionalized silanes equipped. The Incorporation of the glass fibers can be both in the form of short glass fibers as well as in the form of endless strands (rovings) take place.

When particulate fillers are suitable e.g. Soot, Graphite, amorphous silica, Whiskers, alumina fibers, magnesium carbonate (chalk), powdered Quartz, mica, mica, bentonite, talc, feldspar or in particular Calcium silicates such as wollastonite and kaolin. Furthermore, the plastic structures also contain colorants or pigments.

Prefers the aforementioned additives, processing aids and / or Colorant in an extruder or other mixing device at Temperatures from 100 to 320 ° C melted while melting the thermoplastic polymers and discharged. The use of an extruder is particularly preferred in particular a co-rotating, tightly meshing Twin-screw extruder. Process for the preparation of the plastic compositions are known in the art.

2 shows a section through the region of a joint after joining, in the protective element 4 eg the metal component and plastic structure 1 a positive and / or non-positive connection have been received. The in the edge area of the breakthrough 6 raised peripheral edge 8th the limitation of breakthroughs 6 is sharp-edged, allowing it into the plastic structure 1 penetrates. Due to the special design of the peripheral edge 8th the breakthrough 6 penetrates these into the plastic structure 1 a, displaces the plastic structure, which then forms a positive and / or non-positive fit around the drawing edge.

In order to maintain a distance between the protective element and the plastic structure after joining, the surface of the protective element may be in the vicinity of the apertures 6 a depression 5 have symmetrical to the axis of symmetry 10 is trained. The depression 5 can advantageously be cup-shaped, wherein the breakthrough 6 , which has a raised peripheral edge 8th has, is arranged symmetrically in the recess. During the joining process, the sharp-edged peripheral edge penetrates 8th into the plastic structure until the bottom 15 the cup-shaped depression 5 on the plastic structure 1 comes to rest and a sufficient positive and / or non-positive connection between the components 1 respectively. 4 consists.

3 shows a section through the region of a joint after joining, taking on the plastic structure 1 a survey 16 is arranged as a connection surface. An alternative embodiment of a connection point, in order to achieve damping by means of a spacing between the components and to provide sufficient freedom for possible deformations of the protective element, consists of elevations 16 on the side 3 the plastic structure 1 provide, which are advantageously formed during the injection or deep drawing process. The surveys 16 can have any shape, for example, domes or webs. Your base area 18 represents the interface in which the plastic structure is compressed 1 and the protective element 4 eg the metal component, the peripheral edge 8th the breakthroughs 6 penetrates and forms positive and / or non-positive with the plastic structure 1 combines. It is larger than the diameter 6 the peripheral edge 8th , As a result, the joining of the components made of plastic and protective element at the joints is not subject to tight fit accuracies, such as this is necessary in a screw or rivet, whereby the joining process is simplified. The height 19 the survey 16 determines the distance between the plastic structure 1 and the protective element 4 ,

4 shows a section through the region of a joint after joining, wherein a material unsuitable for the joining method by means of a third component whose material is suitable for the joining method, is connected to the plastic structure. The connection of a plastic structure 1 with a protective element 4 against external loads is by means of a third component 20 generated. The material of the third component 20 is suitable to a drawing border 7 to produce on its surface. The component 20 is designed to be a draw 7 over a recess 21 in the protective element 4 protrudes and into the plastic structure 1 of the main body is pressed positively and / or non-positively.

5 shows an oil pan 22 as a preferred embodiment of the composite component according to the invention. The inventive, largely rectangular oil pan 22 is preferably made of a thermoplastic polymer as an injection molded part in one piece. Among other things, the choice of material depends on the conditions to which the oil sump in the Operation is suspended. So it comes in contact with different media such as oil, fuel, coolants and salts. There is a temperature range between -40 ° C up to 150 ° C with a continuous thermal load of 130 ° C. The mechanical stability of the sump is achieved on the one hand by the addition of glass fibers or other fillers, on the other hand, the structure may have stiffening ribs or webs. The oil pan 22 provides a substantially flat interface 24 For example, a trained flange, via which it can be connected to an engine or a motor. Other elements such as internal divisions or components of the oil circulation system can be integrated in the oil sump. On its outer surface 26 are in particular the face 28 , which is inclined in the installed state of the direction of travel and the bottom of the tub 30 facing the roadway is exposed to a shock from rockfall. At these vulnerable surfaces can be arranged with the joining method according to the invention protective elements, which reduce the impact energy of a spin-coated stone by a plastic deformation and not forward to the plastic construction of the oil pan. Preferably, metal plates of ZSTE340, DC01, KT-painted, galvanized sheets, stainless steel sheets or other metals are attached to the vulnerable sites by means of the advantageous joining method. The joining of the metal plate takes place at individual connection points on the surfaces 28 respectively. 30 the oil pan 22 in that the drawing edges produced on the metal plate are pressed into the plastic structure of the oil sump. The number of joints depends on the dimensions of the areas to be protected.

Even the impact load of a joining point a deformation of the metal sheet under the action of a stone impact at the junction, releases not the connection. So in a shock test a test body held the Threefold energy input stood, compared with a pure plastic component. As well proves the connection to temperature changes and a thermal load of 120 ° C as very stable. Compared to the Initial state increased the stability the connection, maybe by the positive influence of the recrystallization of the polymer.

The presented composite component thus offers the possibility of optimally designed Plastic molding adapted to the needs of its function is and with great creative freedom, can be produced inexpensively. For protection against external loads, mechanical, chemical, electrical or thermal nature, can According to the invention, a protective element by means of a simple joining process in the places of the expected load and with an optimized Design later be arranged without the other elements or tight tolerance limits considered Need to become.

1

Plastic structure

3

top

4

protection element e.g. Metal body / metal sheet

5

deepening

6

breakthrough

7

pulling collar-like survey

8th

circumferential edge

9

collar end

10

line of symmetry

11

upper joining tool

12

incident

13

lower joining tool

14

incident

15

ground the depression

16

survey

17

diameter

18

Floor space

19

Height of the survey

20

connecting member

21

recess

22

oil pan

24

interface

26

outer surface

28

face

30

Wannenboden

Claims (11)

Composite component with a base body made of plastic, that at least in areas of an external burden at least has an element for the protection of the main body, which form and / or non-positively with the main body connected is. Composite component according to claim 1, characterized that the at least one element is made to protect the main body a different material than the main body. Composite component according to claim 1 or 2, characterized that the at least one element is made to protect the main body Sheet metal is. Composite component according to one of claims 1 to 3, characterized in that the basic body on the surface, at the at least one element for protecting the base body is arranged over at least has a survey, the one connecting surface for the positive and / or non-positive Composite represents. Composite component according to one of claims 1 to 4, characterized in that the at least an element has a drawing edge with a recess extending symmetrically around the drawing edge. Composite component according to one of claims 1 to 5, characterized in that the base body made of plastic shell-like is trained. Composite component according to one of claims 1 to 6, characterized in that an unsuitable for the joining method material by means of a third component whose material for the joining process is suitable with the main body connected is. Composite component according to one of claims 1 to 7, characterized in that the element for protecting the body against mechanical, chemical, electrical or thermal loads suitable is. Process for producing a composite component according to one of the claims 1 to 6, characterized in that the at least one element for Protection of the body over at least an area features, is arranged on the at least one drawing edge, with a lower sharp-edged peripheral edge and is suitable under pressure to penetrate into a plastic structure of the body to a positive and / or non-positive Composite produce. Method for producing a composite component according to one of the claims 1 to 8, characterized in that the pressure for the penetration of the drawing edge is generated in the plastic structure in the join together tools, in each of which the main body made of plastic and the at least one element for protection, which over at least an area with at least one drawing edge, are inserted, so that the drawing edge pressed positive and / or non-positively into the plastic structure becomes. Use of composite components according to one of claims 1 to 8 in the automotive, aircraft or shipbuilding or manufacturing of household or electrical appliances.