DE102010025618A1 - Connecting arrangement and method for its production - Google Patents

Abstract

The invention relates to a connection arrangement (22) of a fiber-reinforced composite component (10) with a further, at least partially metallic component (24), in which the composite component (10) has at least one metallic reinforcing fiber (12) embedded in a plastic matrix (14), which projects beyond an end region (18) of the composite component (10), the at least one metallic reinforcing fiber (12) being integrally connected, in particular welded or soldered, to the further component (24). The invention further relates to a method for producing such a connection arrangement (22). The connection arrangement (22) and the method enable the use of conventional welding methods for joining fiber composite components (10), which both facilitates the manufacture and repair of such connection arrangements (22) and makes them more cost-effective.

Description

The invention relates to a connection arrangement of a fiber-reinforced composite component with a further component according to the preamble of patent claim 1 and a method for producing such a connection arrangement. The invention further relates to a method for repairing such a connection arrangement.

In motor vehicle construction, increasing fiber-reinforced composite components are used due to lightweight construction considerations. Such components comprise a matrix of a plastic in which reinforcing fibers are embedded. As a result of the reinforcing fibers, such composite components have a particularly good tensile strength in the fiber direction and at the same time a very low weight.

Since such composite components are usually used only for partial areas of a motor vehicle body, it is necessary in body construction to create connections between fiber-reinforced composite components and other components of the motor vehicle body. For this purpose, positive or non-positive joining methods are usually selected. For example, fiber-reinforced composite components can be bonded together or with metallic body components or connected with the aid of mechanical joining elements such as screws, bolts, rivets or the like.

From the DE 10 2007 023 836 A1 Furthermore, a method for producing a compound of a fiber-reinforced components with another component is known. The fiber-reinforced component has reinforcing fibers which protrude beyond an end region of the component. The connection is made by embedding the protruding reinforcing fibers in the second component. This can be realized by pouring the protruding fibers into the second component. The DE 10 2007 023 836 A1 also describes a rolling in of the protruding fibers between two semi-finished sheet metal, which are then welded together. The protruding fibers of the fiber composite component are thereby frictionally held between the mutually rolled and welded together semi-finished sheet metal.

The known methods for producing such connection arrangements are either complex in their implementation or lead to only limited durable connections of the respective components. If damage occurs to one of the components, then as a rule the entire connection arrangement must be replaced, since a partial repair is rarely possible due to the joining methods used.

The present invention is therefore based on the object to provide a simple to manufacture, mechanically stable and easily repairable connection arrangement between a fiber-reinforced composite component and another component according to the preamble of patent claim 1. A further object of the present invention is to provide a simple and inexpensive method for producing such a connection arrangement, as well as a simple and cost-effective method for repairing such a connection arrangement.

This object is achieved by a connection arrangement having the features of patent claim 1, a method for producing a connection arrangement having the features of patent claim 5 and by a method for repairing a connection arrangement having the features of patent claim 9.

Such a connection arrangement comprises a fiber-reinforced composite component and a further, at least partially metallic component. The composite component has at least one metallic reinforcing fiber embedded in a plastic matrix, which protrudes beyond an end region of the composite component. According to the invention, a connection between the composite component and the further component is provided by the fact that the at least one metallic reinforcing fiber is materially connected to the further component, in particular welded or soldered.

For the preparation of such a connection arrangement so neither expensive process for embedding the protruding reinforcing fibers in the further component, nor mechanical joining elements are necessary. Rather, the connection can be made with conventional cohesive methods, as are customary for joining metallic components. The fiber-reinforced composite component can be processed in the manufacture - and also in the repair - of such a connection arrangement as a conventional metallic body component. The welding or soldering can be done by a conventional robot, so that no investment in expensive new tools are necessary. At the same time, the connection between the two components is particularly strong and durable due to the material bond.

The connection arrangement according to the invention not only allows the integration of fiber-reinforced composite components in metallic bodies, but they can also find application for connecting composite components with each other. For example, it is possible to form two composite components with respective protruding metallic reinforcing fibers Add connection arrangement. The further component may also be a plastic component with cast-metallic inserts or a metallic coating, which are also welded to the protruding reinforcing fibers of the composite component.

In a preferred embodiment of the invention, the fiber-reinforced composite component has a plurality of metallic reinforcing fibers, which respectively project beyond the end region of the composite component. These fibers are connected to one another to a joining element, which is materially connected to the other component, in particular welded or soldered. The fibers can, for example, be twisted, braided or already welded together. As a result, a particularly stable joining surface for connecting the components is created with each other. The shape of the joining element can be chosen freely depending on the type of connection arrangement. For example, the protruding fibers can form a flange.

By forming the protruding fibers into a joining element, an additional positive connection between the components can furthermore be provided. For example, the joining element may have the shape of an eyelet, which encloses a corresponding counterpart of the further component. The combination of material bond and form-fit a particularly stable connection arrangement is obtained.

In a further embodiment of the invention, a metallic Hilfsfügeelement is arranged in a connection region between the fiber-reinforced composite component and the further component and materially connected to the at least one metallic reinforcing fiber and / or the other component, in particular welded or soldered. Such a Hilfsfügeelement can further increase the strength of the connection assembly. At the same time, the auxiliary joining element can be designed as a stop or centering element, so that the production of such a connection arrangement is particularly reliable.

The invention further relates to a method for producing a connection arrangement of a fiber-reinforced composite component with a further, at least partially metallic component. For this purpose, a composite component is used, which has at least one metallic, embedded in a plastic matrix reinforcing fiber. To produce such a connection arrangement, according to the invention, a section of the at least one metallic reinforcing fiber which projects beyond an end region of the composite component is connected in a materially bonded manner to the further component, in particular welded or soldered.

The method according to the invention thus makes it possible to join fiber-reinforced composite components with methods known from metal processing. Thus, for example, can be made in the simplest way motor vehicle bodies that include both purely metallic and composite components. Since the welding can be carried out by conventional welding robots, it is also possible to manufacture different body variants, in which a specific component is alternatively designed as a metal component or composite component in the same production line, without the joining tools must be replaced or reconfigured.

Moreover, it is also possible to use a further component, which is designed as a composite component. The only prerequisite for carrying out the method according to the invention is the presence of a weldable metal region in a joining zone of the further component. Thus, by means of the method described, a plurality of composite components with metallic reinforcing fibers can be connected to one another. Also plastic components with metallic inserts or metallic coatings can be welded in the manner described with composite components with protruding metallic reinforcing fibers.

In a preferred embodiment of the invention, before the joining of the composite component with the further component, a plurality of metallic reinforcing fibers projecting beyond the end region of the composite component are connected to one another to form a joining element. The joining element thus formed is finally materially connected to the other component, in particular welded or soldered. On the one hand, this creates a particularly stable joint connection between the composite component and the further component. On the other hand, this makes it possible to create almost any joining geometries on the composite component. The metal fibers projecting beyond the end region of the composite component can be connected to one another, for example by twisting, braiding or else by materially joining, and bent into the desired shape. In this way, for example, metallic terminations for the end portion of the composite component, flanges, eyelets, hooks or the like can be formed.

It is particularly expedient to form the joining element of the composite component so that it can take on an additional positive connection function. After forming such a joining element is first of Formed fit between the composite component and the other component. For example, a joining element designed as an eyelet can be placed around a complementary structure of the further component. After the positive connection has been made, the actual integral joining takes place, for example by welding the joining element to the further component. Overall, a particularly firm connection is created, since the positive connection and the material complement each other.

In a further embodiment of the invention, a metallic auxiliary joining element is arranged in a connecting region of the two components prior to the integral connection of the composite component with the further component. This may be, for example, insert or circulating parts, which can serve as stops or centering and at the same time contribute to the strength of the resulting compound. The auxiliary joining element may be used to indirectly interconnect the metallic reinforcing fibers and the further component, however, the reinforcing fibers and the further component may also be directly welded together, the auxiliary joining element providing an additional connection between the components and both the reinforcing fibers, also welded to the other component.

Finally, the invention also relates to a method for repairing a connection arrangement of a fiber-reinforced composite component with a further, at least partially metallic component, which in a joining region via at least one metallic, embedded in a plastic matrix of the composite component reinforcing fiber, which protrudes beyond an end region of the composite component, with each other materially are connected. In order to repair such a connection arrangement, it is provided according to the invention to first cut out a partial area of the connection arrangement which comprises a damaged area as well as the joining area. The damaged area is then replaced by a repair component, which is materially connected, in particular welded, both to the at least one metallic reinforcing fiber and to the further component.

The method according to the invention permits the section repair of connection arrangements which comprise at least one fiber-reinforced composite component without weakening the connection arrangement by adhesive bonds, as is the case in many repair methods known from the prior art. The welded connections between the repair component and the remaining regions of the composite component and further component rather a repaired connection arrangement is created, which corresponds in strength to the original connection arrangement. This makes it possible to partially repair existing car bodies consisting of composite materials, without the need for a costly replacement of complete parts or assemblies, while ensuring the strength and stability of the body remains guaranteed.

In the following, the invention and its embodiments will be explained in more detail with reference to the drawing. Showing:

1 A fiber-reinforced composite component for use in one embodiment of a connector assembly according to the invention;

2 An alternative fiber-reinforced composite component for use in an embodiment of a connector assembly according to the invention;

3 An embodiment of a connection arrangement according to the invention;

4 An alternative embodiment of a connection arrangement according to the invention;

5 An alternative embodiment of a connection arrangement according to the invention with additional auxiliary joining element;

6 An alternative embodiment of a connection arrangement according to the invention with additional auxiliary joining element;

7 An alternative embodiment of a connection arrangement according to the invention with additional positive locking;

8th An alternative embodiment of a connection arrangement according to the invention with additional encompassing Hilfsfügeelement;

9 An alternative tubular fiber reinforced composite component for use in one embodiment of a connector assembly according to the invention;

A fiber-reinforced composite component 10 ( 1 ) comprises a plurality of metallic reinforcing fibers 12 which are in a plastic matrix 14 are included. To the connection of the composite component 10 to facilitate with other, partially metallic components, is a subsection 16 the reinforcing fibers 12 over an end area 18 the composite component over. The protruding section 16 The metallic reinforcing fibers can be used to reinforce the fibers 12 , and thus the composite component 10 , by welding with other metallic components too connect. As a result, expensive adhesive connections or the use of mechanical joining elements such as screws, rivets or the like can be dispensed with.

As 2 shows, the protruding sections 16 the metallic reinforcing fibers 12 to a joining element 20 be connected, which has a metallic finish for the end 18 of the composite component 10 forms. For this purpose, the reinforcing fibers 12 bent into the desired geometry, twisted or intertwined with each other, or welded together. The joining element 20 thus provides a metallic joining surface, which can be machined with conventional, known from metalworking joining process.

Like such a joining element 20 for making a connection assembly 22 can be used is in 3 shown. The connection arrangement 22 includes next to the composite component 10 another component 24 , which also as composite component with metallic reinforcing fibers 12 is trained. Also with the component 24 are protruding area of reinforcing fibers 12 to a joining element 20 summarized. Both components 10 . 24 So have a metallic finish in the form of joining elements 20 that in the connection arrangement 22 meet on impact and welded together. The other component 24 may be a metal fiber reinforced plastic component, a metallic cast component, a metallic sheet metal forming part, etc.

4 shows an alternative geometry of the joining elements 20 in a connection arrangement 22 , The joining elements 20 extend here only over half the width of the components 10 . 24 and are laterally offset from each other. This is when welding the joining elements 20 a larger weld length available. In addition, by the geometry shown, the joining elements 20 an axial course of the weld allows, which optionally has advantages over the vertical course of the weld in the embodiment according to 3 can offer.

In the embodiment of the connection arrangement 22 according to 5 will be the connection between the two components 10 . 24 by an additional metallic auxiliary joining element 26 strengthened. To connect the two components 10 . 24 are first the protruding areas 16 the respective metallic reinforcing fibers 12 welded together. The helper element 26 is in respective recesses of the components 10 . 24 in their connection area 30 inserted and also with the protruding areas 16 the reinforcing fibers 12 welded. The helper element 26 stabilizes the connection arrangement 22 mechanically and used in the manufacture of the connection arrangement 22 at the same time as a stop element, which the components 10 . 24 keeps each other at the desired distance.

As 6 shows, the auxiliary joining element 26 also with a thigh 32 between the components 10 . 24 extend. Again, this is the auxiliary 26 again in recesses 28 in the connection area 30 of the components 10 . 24 taken and can also serve as a stop element. In contrast to the embodiment according to 5 the connection of the components takes place 10 . 24 here indirectly. The protruding areas of the reinforcing fibers 12 are not directly welded together, but rather each with the thigh 32 of the auxiliary footing 26 , which is a bridge between the components 10 . 24 forms.

In addition to the integral connection of the components 10 . 24 by welding can also be provided a positive connection, as in 7 shown. The reinforcing fibers 12 of the composite component 10 form an eyelet here 34 in which a complementary form-locking element 36 of the further component 24 is included. In addition, the reinforcing fibers 12 with the positive-locking element 36 welded. The combination of form-fitting and material connection gives the connection arrangement 22 a particularly high strength.

8th shows a further alternative embodiment of the connection arrangement 22 , The other component 24 is here designed as a final cap, which is the end 18 encloses the composite component. The other component 24 is completely metallic and with the metallic reinforcing fibers 12 of the composite component 12 welded. The end cap provides a connection option for other components, which are particularly strong welds possible.

As 9 shows, the described method for joining composite components is limited 10 not on the solid profile components shown in the previous figures. Also fiber reinforced tubes 10 can be connected in the described way with other components. 9 shows here by way of example a fiber-reinforced tube, whose in a section 16 over the end area 18 of the tube protruding fibers 12 to an eyelet 34 ' are formed, via which the tube can be material and positively connected to other components.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102007023836 A1 [0004, 0004]

Claims (9)

Connection arrangement ( 22 ) of a fiber-reinforced composite component ( 10 ) with a further, at least partially metallic component ( 24 ), in which the composite component ( 10 ) at least one metallic, in a plastic matrix ( 14 ) embedded reinforcing fiber ( 12 ) which has an end region ( 18 ) of the composite component ( 10 protruding, characterized in that the at least one metallic reinforcing fiber ( 12 ) cohesively with the further component ( 24 ), in particular welded or soldered. Connection arrangement ( 22 ) according to claim 1, characterized in that the fiber-reinforced composite component ( 10 ) a plurality of over the end region ( 18 ) protruding metallic reinforcing fibers ( 12 ), which mutually to a joining element ( 20 ), which cohesively with the other component ( 24 ) connected is. Connection arrangement ( 22 ) according to claim 2, characterized in that the joining element ( 20 ) in addition positively with the other component ( 24 ) connected is. Connection arrangement ( 22 ) according to one of claims 1 to 3, characterized in that in a connection region ( 30 ) between the fiber-reinforced composite component ( 10 ) and the further component ( 24 ) a metallic auxiliary joining element ( 26 ) arranged with the at least one metallic reinforcing fiber ( 12 ) and / or the further component ( 24 ) is materially connected, in particular welded or soldered. Method for producing a connection arrangement ( 22 ) of a fiber-reinforced composite component ( 10 ) with a further, at least partially metallic component ( 24 ), in which at least one metallic, in a plastic matrix ( 14 ) embedded reinforcing fiber ( 12 ) of the composite component ( 10 ), which have an end region ( 18 ) of the composite component ( 10 ) protrudes, with the further component ( 24 ) materially connected, in particular welded or soldered. A method according to claim 5, characterized in that prior to the integral connection of the components ( 10 . 24 ) a plurality of over the end region ( 18 ) protruding metallic reinforcing fibers ( 12 ) of the composite component ( 10 ) to a joining element ( 20 ), which is subsequently connected to the further component ( 24 ) materially connected, in particular welded or soldered. A method according to claim 6, characterized in that the joining element ( 20 ) in addition positively with the other component ( 24 ) is connected. Method according to one of claims 5 to 7, characterized in that in a connection region ( 30 ) between the fiber-reinforced composite component ( 10 ) and the further component ( 24 ) a metallic auxiliary joining element ( 26 ) arranged with the at least one metallic reinforcing fiber ( 12 ) and / or the further component ( 24 ) materially connected, in particular welded or soldered. Method for repairing a connection arrangement ( 22 ) of a fiber-reinforced composite component ( 10 ) with a further, at least partially metallic component ( 24 ), which in a joining region via at least one metallic, into a plastic matrix ( 14 ) embedded reinforcing fiber ( 12 ) of the composite component ( 10 ), which have an end region ( 18 ) of the composite component ( 10 ) protrude, are materially interconnected, characterized in that a portion of the connection arrangement ( 22 ), which comprises a damaged area and the joining area, is cut out and replaced by a repair part, which is connected to both the at least one metallic reinforcing fiber ( 12 ) as well as with the further component ( 24 ) materially connected, in particular welded or soldered.

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