DE102010053957A1 - Method for manufacturing hybrid component, particularly for body of passenger car, involves connecting two components, particularly metal components or fiber composite components, with each other - Google Patents

Abstract

The method involves connecting two components, particularly metal components (12,14) or fiber composite components, with each other. The components are partially made of plastic. The two components are connected with each other through a hollow rivet-connection. A hybrid component (10) is formed by combined forming and plastic injection molding, particularly by combined hydro-forming and plastic injection molding.

Description

The invention relates to a method for producing a hybrid component according to the preamble of claim 1. Furthermore, the invention relates to a hybrid component according to the preamble of patent claim 10.

Hybrid components are known, for example, in the mass production of passenger cars in a wide range of applications. Thus, such hybrid components are used, for example, in structural parts such as door carriers, front end supports or bender crossbeam for bumpers in a variety of applications. The main advantage of such hybrid components is that they are on the one hand relatively low-weight and on the other hand extremely needs-based. In particular, the insert or metal components and / or fiber composite components provide for sufficient stability of the hybrid components. The plastic, which is usually molded onto the metal components and / or fiber composite components, provides on the one hand for a corresponding stiffening, for example by ribs or the like and on the other hand for a corresponding functional integration, so that the plastic, for example, appropriate recordings, contact surfaces, or the like for fixing and may have attachment to or from connection components.

Furthermore, it is known from the prior art to fasten such metal components to each other via a plurality of possible connections. An example of such a connection is from the DE 101 51 659 B4 to be known as known. In this case, one of the metal components is perforated accordingly. The unperforated component is plastically deformed by means of a pressure fluid through the corresponding hole of the perforated member into a cavity of the mold. In a further joining step, the plastically deformed region of the component is reshaped by a punch, which counteracts the pressure fluid, so that an undercut is formed between the metal components.

Object of the present invention is to provide a method and a hybrid component of the type mentioned, in which the respective components, in particular metal components and / or fiber composite components are mechanically highly resilient connected to each other and in which a particularly fast and easy production of Hybrid components can be realized.

This object is achieved by a method and a hybrid component having the features of patent claims 1 and 10, respectively. Advantageous embodiments with expedient and non-trivial developments of the invention are specified in the remaining claims.

In order to provide a method of the aforementioned type, by means of which can be mechanically highly resilient connect the components, in particular metal components and / or fiber composite components, the hybrid component and which also ensures that the hybrid component can be made extremely quickly and easily, it is The invention provides that the at least two components are connected to one another via at least one hollow rivet connection before they are provided with plastic to form the final hybrid component. Such a hollow rivet connection has the particular advantage that the metal components to be joined or the like. Components can be extremely stable and rigid connected to each other. This can be done in particular without heat supply by setting the corresponding hollow punch rivet. In particular, when setting the hollow rivet it is achieved that the rivet shank spreads and forms a closing head in the corresponding metal components. The Hydro hollow punch rivets are made for example by cold extrusion, by exciting withdrawal or striking. Such a connection method is particularly advantageous when a closed hollow profile part with an open profile part, such as a sheet metal to be connected. Such a constellation is often given especially in structural components of bodies of passenger cars, such as door carriers, front end supports or bender crossbeams for bumpers.

The method described is particularly suitable when relatively little space is available for the delivery of the hollow punch rivets, for example because corresponding plastic ribs or similar plastic elements are provided in the region of the respective hollow rivet connection.

In a further embodiment of the invention, it has been found to be advantageous if the hybrid component in a combined forming and plastic injection molding, in particular a combined hydroforming and plastic injection molding process is prepared. By such a method, the hybrid component is particularly stressful as well as fast and inexpensive to produce.

A further advantageous embodiment provides that at least one hollow punch rivet is prefixed to one of the metal components outside a tool which generates the hollow punched rivet connection. Such a prefix is suitable in particular, if there is too little space for the supply of hollow punch rivets available.

It has been found in a further embodiment of the invention to be particularly advantageous if a receiving opening in the corresponding component, in particular metal component and / or fiber composite component, is introduced before the prefixing of the respective hollow punch rivet. In other words, therefore, the respective component is first pre-punched or pre-punched and then prefixed with the hollow punch rivet in the corresponding hole. For this purpose, if necessary, an expanding mandrel can be used with which the hollow punch rivet is slightly spread open and thus particularly securely fixed to the corresponding metal component and / or fiber composite component. Alternatively, it is also conceivable that the corresponding metal component and / or fiber composite component, to which the hollow punch rivet is to be prefixed, is not pre-punched or pre-punched. In this case, the rivet is pressed into the corresponding metal component and / or fiber composite component, and only so far that it terminates at most flush on the corresponding later exit side.

A further advantageous embodiment provides that at least one hollow punch rivet via a gripper device to a hollow punch rivet connection generating. Tool will be supplied. Such a gripper device is particularly suitable for correspondingly positioning a plurality of hollow punch rivets when the tool is open, so that they can be correspondingly pressed and shaped in the combined hydroforming and plastic injection molding process with the mold closed in such a way that the individual hollow punch rivet connections are formed between the corresponding metal components ,

Alternatively, it is provided in a further embodiment of the invention that at least one hollow rivet is fed via a rivet feed device to a die producing the hollow rivet connection. Such a method is particularly suitable if sufficient space can be provided for the supply within the tool.

In a further embodiment of the invention, at least one hollow punch rivet is used, whose head terminates flush with a component surface of the corresponding component after producing the hollow punched rivet connection. Thus, a plane or smooth functional surface can be provided following the production of the hollow punched rivet connection.

Alternatively, it is also possible to use a hollow punch rivet whose head protrudes from a component surface of the corresponding component after production of the hollow punched rivet connection. In this case, the head can be used for a magazine feed. This is possible because the head can be used as a guide surface in the tool.

The advantages described above in connection with the method according to the invention apply in the same way to the hybrid component according to claim 10.

Further advantages, features and details of the invention will become apparent from the following description of preferred embodiments and from the drawings; these show in:

1 a perspective view of a trained as a hybrid door carrier for a body for a passenger car, in which a plurality of metal components and / or fiber composite components are interconnected and at least partially provided with plastic, wherein respective metal components and / or fiber composite components of the hybrid component via a A plurality of hollow rivet joints are interconnected and then provided with plastic in a combined hydroforming and injection molding;

2a and 2 B a fragmentary perspective view and a fragmentary sectional view taken along the line IIb-IIb in 2a by one of the metal components and / or fiber composite components, to which a plurality of hollow punch rivets have been pre-fixed outside of a die producing the hollow rivet joints;

3a and 3b respective sectional views through a pre-fixed to the corresponding metal component and / or fiber composite component hollow punch, wherein according to 3a before the pre-fixed hollow rivet a receiving opening has been introduced into the corresponding metal component and / or fiber composite component, and wherein according to 3b the hollow punch rivet has been prefixed to the metal component and / or fiber composite component without prior introduction of a receiving opening;

4 respective sectional views on hollow rivets according to two embodiments, which have been introduced into a corresponding metal component and / or fiber composite component, wherein the head of the left Hohlstanzniets after producing the Hohlstanznietverbindung with a component surface of the corresponding metal component and / or fiber composite component flush with the surface, and wherein the head of the hollow rivet shown on the right protrudes from the component surface of the corresponding metal component and / or fiber composite component after producing the hollow rivet connection;

5 a sectional view and a bottom view of a possible embodiment of the hollow punch rivet, which is presently designed as Halbhohlstanzniet with slotted rivet shank;

6 a front view of a metal component in the form of an open profile or sheet metal part, which is fastened by mediation of a plurality of hollow rivet on the other metal component and / or fiber composite component in the form of a closed hollow profile part, wherein the two metal components and / or fiber composite components additionally provided with plastic;

7 a perspective view of a tool for producing a door carrier according to 1 , In addition, wherein a gripping device can be seen, via which a plurality of hollow rivets are supplied to the tool generating the hollow rivet joints;

8a and 8b respective schematic sectional views of the tool according to

7 with respective punches for producing the corresponding hollow rivet joints, wherein the hollow punches are received within each corresponding receptacles;

9 a perspective view of a punching head of a rivet feed device via which the respective hollow punch rivets are brought into the opened tool; and in the

10a and 10b in each case a fragmentary and schematic sectional view through the tool with the rivet feed device and the punching head, by means of which the hollow punch rivet connections can be produced.

In 1 is a hybrid component in a perspective view 10 represented for a body for a passenger car. More specifically, it is the hybrid component 10 around a door carrier a side of the motor vehicle, which is equipped inter alia with an outer panel and an interior trim.

The hybrid component 10 includes a substantially U-shaped metal component 12 which is present as a closed hollow profile part - for example, from an extruded profile, which has subsequently been converted - is formed. With this metal component 12 are a plurality of other metal components 14 . 16 . 18 connected in the form of corresponding support elements in a manner described in more detail below. These metal components 14 . 16 . 18 are designed as open profile parts or correspondingly shaped profile surface.

The hybrid component 10 or the metal components 12 . 14 . 16 . 18 are at least partially with a plastic 20 provided by which, for example, ribs 22 or functional areas or functional elements such as screw receptacles, brackets, bearings or the like may be formed. In the present embodiment can as plastic 20 For example, be provided a preferably fiber-reinforced polyamide material.

Alternatively, the hollow profile part may also be formed from a FRP material, in particular at least partially from unidirectionally extending long fibers made of carbon. The hollow profile may be a textile which is present as a woven or knitted fabric. The matrix can be duroplastic or thermoplastic.

Based on 2a and 2 B Now, the concrete definition of the metal component 14 on the metal component 12 exemplified: this shows 2a in a fragmentary and enlarged perspective view of the metal component 14 in its attachment area with the metal component 12 , 2 B shows a sectional view taken along the line IIb-IIb in 2a ,

Out 2a is particularly apparent that the metal component 14 over several hollow punch rivets 24 on the metal component 12 is attached. How out 2a recognizable, but show the representations according to the 2a and 2 B the respective hollow punch rivets 24 in a pre-fixed position. This means that the hollow punch rivets 24 already outside of a tool producing the hollow punch rivet connections on the corresponding metal component 14 are pre-fixed. More specifically, in the present case, the respective hollow punch rivets 24 , which are designed here as semi-hollow punch rivets, in the stamp-side metal component 14 or metal sheet prefixed.

In the 3a and 3b are in a respective schematic sectional view of possible variants of the prefixing of the respective hollow punch rivet 24 shown. The hollow punch rivets are doing to the corresponding joints with the metal sheet or metal component 14 in a punching tool (follow-on composite tool) fed via punching heads and conventional feeding technology.

Like now off 3a can be seen, a fastening variant is shown in the present case, in which the sheet metal or the metal component 14 first pre-punched or pre-punched and then in a following station of the hollow punch rivet 24 via a punching head and a corresponding parts provision in a corresponding pre-punched or pre-punched receiving opening 26 has been introduced or fixed. This fixing process can by a dashed line indicated expanding mandrel 28 be supported, which a riveting 30 of the hollow punch rivet 24 accordingly erhiet and thus for a secure pre-fixing to the metal component 14 provides. The hollow punch rivet 24 is at most as far into the receiving opening 26 introduced until this with one of the die side of the sheet metal or metal component 14 facing broadside 32 flush. In other words, the hollow punch rivet 24 the sheet metal or metal component 14 not penetrate in such a way that its riveting 30 opposite the corresponding broadside 32 survives.

In the variant according to 3B is the hollow punch rivet 24 prefixed without pre-punching, again at most so far that this is not opposite the broadside 32 on the die side of the sheet metal or metal component 14 survives. A by the punching of the hollow punch rivet 24 resulting stamping 34 is doing, for example, in the cavity of the hollow rivet 24 added.

In 4 are two possible positions of the respective hollow rivet 24 after preparation of the hollow punch rivet connection shown. In the left illustration of 4 is a hollow punch rivet 24 represented, whose head 36 after producing the hollow punched rivet connection with a component surface 38 of the corresponding metal component 14 flush with the surface. In this case, a flat functional surface is created. For the in 4 right case a hollow punch rivet is used whose head 36 after producing the hollow punched rivet connection from the component surface 38 of the corresponding metal component 14 sublime protrudes. In this case, the head 36 be used for a magazinized rivet feed. This is possible because of the head 36 can be used as a guide surface in the tool.

The 5 shows in a sectional view and a bottom view corresponding embodiments of the hollow punch rivet 24 , The hollow punch rivet 24 can have a special rivet geometry with a very small ratio between the length and its diameter. Furthermore, the rivet shank 30 optionally - as in 5 on the right is slotted, which causes the shaft end of the rivet shaft 30 in an improved manner positively with the respective component - for example, the metal component 12 - connects or bounces into it. Particularly advantageously, the Verkrallung or solidification in fiber composite semi-finished products and such semi-finished products, which are reinforced by steel strands and / or steel fibers occur.

In 6 is a fragmentary front view of the arrangement of the metal component 14 on the metal component 12 according to 1 or the 2a and 2 B shown after the designed as Hydrohalbhohlstanzniete hollow punch rivet 24 respectively deformed accordingly and thereby with the metal component 12 after the manufacture of the hollow rivet joints, the metal components 12 . 14 with the plastic 20 have been provided. The actual joining process has been carried out in a manner described in more detail below in a hydroforming injection molding tool. It can be seen that directly next to the hollow punch rivets 24 respective ribs 22 of the plastic 20 run and thus little space for the supply of hollow punch rivets 24 is available.

In 7 Figure 3 is a perspective view of an open hydroforming injection molding tool 40 recognizable. In addition, one possible concept of rivet provision by a gripping device 42 recognizable, in which the Hydrohalbhohlstanzniete 24 first be positioned in a gripper via pickup mandrels. With the aid of this gripper, all semi-hollow punch rivets are then made 24 into the opened tool 40 brought to the appropriate joints. This process can be used for both mold halves of the tool 40 be performed.

The inclusion of hollow punch rivets 24 in the tool 40 takes place via respective, in the 8a and 8b recognizable rivet recordings 46 which are within the corresponding tool half 48 of the tool 40 are arranged. In the 8a and 8b These are rivet shots 46 just as recognizable as the metal components to be joined 12 . 14 ,

The respective rivet holder 46 is in each case a corresponding stamp 50 assigned, by means of which the respective associated hollow punch rivet 24 in the respective corresponding wall of the metal components 12 respectively. 14 is driven. The present embodiment differs from that according to the 2a and 2 B such as 3a and 3b in particular in that in the present case the hollow punch rivets 24 not on the metal component 14 are pre-fixed. Rather, in the present case, the positioning is effected by the exact arrangement within the corresponding rivet receptacle 46 ,

In 8b are possible facilities within the rivet 46 recognizable, by means of which the corresponding hollow punch rivet 24 can be kept in place. In the upper part of 8b is in the Sectional view of a rotating magnetic ring 56 recognizable by means of which the positioning of the hollow punch rivet 24 he follows. In the lower part of 8b is an alternative to the magnetic ring 56 a spring arrangement with respective springs 58 recognizable, over which the corresponding hollow punch rivet 24 to hold in place.

The joining of the metal components 12 . 14 takes place by appropriate method of the stamp 50 , wherein the die by a pressurized fluid 60 with which the designed as a hollow profile metal component 12 is subjected to an internal high pressure is formed. The over the stamp 50 applied with a pressing force hollow punch rivet 24 cut in a first phase of the joining process, the punch-side metal component 14 , In this case, the punched joint 34 in the cavity of the hollow punch rivet 24 is recorded. With the further penetration of the hollow punch rivet 24 - Especially designed as a hollow profile and with the pressurized fluid 60 loaded metal component 12 - spreads the rivet 30 on and forms in hydroforming joining part, namely the metal component 12 , a closing head, said metal component 12 from the rivet foot or rivet shank 30 not completely cut. This creates the definition of the two metal components 12 . 14 together. This can be done by pressurizing with the pressurized fluid 60 the hydroforming of the metal components, in particular of the metal component 12 respectively. The hydroforming of the metal components 12 . 14 . 16 . 18 can before, during or after the introduction of the hollow punch rivet 24 respectively.

Following the hydroforming and the connection of the metal components 12 . 14 . 16 . 18 is then in the in 7 illustrated tool 40 an injection molding process performed in which the metal components 12 . 14 . 16 . 18 at least partially with the plastic 20 be provided to achieve here by a sufficient stiffening or the formation of individual functional components such as recordings, consoles or the like.

Overall, it can be seen that in this case the rivet 24 each deformable stamp 50 be pressed, wherein by means of the pressurized fluid 60 , which may be, for example, a gas or water emulsion, within the closed profile of the metal component 12 is held against.

In 9 is a punching head in a perspective view 62 represented, via which by means of feed rails or supply hoses, which, for example, at the receptacle 64 of the punching head 62 can be connected, the rivet 24 can be brought into the open hydroforming injection molding tool.

In the 10a and 10b is in each case in a schematic sectional view of the tool 40 with a corresponding rivet feed device 66 shown. In particular, it can be seen in addition to the rivet feed device 66 respective stamp 68 , by means of which the corresponding metal component 12 for pressurizing with the pressurized fluid 60 can be closed. About the rivet feed device 66 are the hollow punch rivets 24 in the corresponding rivet shots 46 to bring so that these by means of the corresponding stamp 50 in the respective walls 52 respectively. 54 corresponding metal components 12 respectively. 14 can be introduced.

Overall, it can be seen that by the present method, the problem of feeding and prefixing hydroforming suitable rivets 24 and putting or pushing in the rivet 24 in the metal components to be joined 12 to 18 is to be solved. The entire process takes place in a hydroforming injection molding tool, wherein initially by the hollow punch rivet connections, the corresponding metal components 12 be joined together and then by injection molding the appropriate plastic 20 is introduced. The closed and open profiles are over the rivet 24 - By means of the pressure fluid 60 - via the pressure generated in the hydroforming process, via movable punches 50 and pressure connected. After the connection, the respective metal components 12 to 18 encapsulated with plastic at a plurality of joints of the structural assembly. This results in a reduction in the cost and weight of the corresponding hybrid component 10 and a reduction in operating costs. Here is a process-reliable and stable prefixing of the metal components 12 to 18 and a reliable feed of the rivet 24 given. The component geometry enables a flexible rivet fixing option as a modular system. The result is an increase in the number of realizable in the series tool joints for complex assemblies such as door support, bending beams of bumpers or front end supports. This also gives a favorable feasibility of crash and highly loaded structure and semi-structures with high rigidity and high reliability.

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 10151659 B4 [0003]

Claims (10)

Method for producing a hybrid component ( 10 ), in particular for a body of a passenger car, in which at least two components, in particular metal components ( 12 . 14 ) and / or fiber composite components, connected together and at least partially with a plastic ( 20 ), characterized in that the at least two components ( 12 . 14 ) are connected to one another via at least one hollow rivet connection, before they are connected to the plastic ( 20 ). Method according to claim 1, characterized in that the hybrid component ( 10 ) is produced in a combined forming and plastic injection molding process, in particular a combined hydroforming and plastic injection molding process. Method according to claim 1 or 2, characterized in that at least one hollow punch rivet ( 24 ) outside a die producing the hollow punched rivet joint ( 40 ) on one of the components ( 14 ) is prefixed. A method according to claim 3, characterized in that prior to the prefixing of the hollow punch rivet ( 24 ) a receiving opening ( 26 ) into the corresponding component ( 14 ) is introduced. Method according to claim 1 or 2, characterized in that at least one hollow punch rivet ( 24 ) via a gripper device ( 42 ) a tool producing the hollow punched rivet connection ( 40 ) is supplied. Method according to claim 1 or 2, characterized in that at least one hollow punch rivet ( 24 ) via a rivet feed device ( 66 ) a tool producing the hollow punched rivet connection ( 40 ) is supplied. Method according to one of the preceding claims, characterized in that as components ( 12 . 14 ) a closed hollow profile part is connected to an open profile part. Method according to one of claims 1 to 7, characterized in that at least one hollow punch rivet ( 24 ) whose head ( 36 ) after producing the hollow punched rivet connection with a component surface ( 38 ) of the corresponding component ( 14 ) completes flush with the surface. Method according to one of claims 1 to 7, characterized in that at least one hollow punch rivet ( 24 ) whose head ( 36 ) after producing the hollow punched rivet connection from a component surface ( 32 ) of the corresponding component ( 14 ) protrudes sublime and / or its riveting 30 for improved engagement of the shank end of the rivet shank ( 30 ) is executed slotted. Hybrid component ( 10 ), in particular for a body of a passenger car, with at least two interconnected and at least partially with a plastic ( 20 ) provided components ( 12 . 14 ), in particular metal components ( 12 . 14 ) and / or fiber composite components, characterized in that the hybrid component ( 10 ) is produced in a method according to one of claims 1 to 9.

Images