DE102018207211A1 - Hybrid steel-plastic semi-finished product with shielding properties - Google Patents

Abstract

The invention relates to a thermoformable, platinen- or band-shaped semi-finished product for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, the at least one electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields shielding, platinen- or band-shaped metal sheet and at least one on the metal sheet cohesively applied thermoplastic, thermosetting or elastomeric plastic layer, a method for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, the use of the semifinished product according to the invention for producing a three-dimensionally shaped hybrid component as a component, and a method for shielding electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields.

Description

Technical area

The invention relates to a thermoformable, platinen- or band-shaped semi-finished product for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, the at least one electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields shielding, platinen- or band-shaped metal sheet and at least one on the metal sheet cohesively applied thermoplastic, thermosetting or elastomeric plastic layer, wherein the metal sheet has a specific composition and the semifinished product a screen factor S (v) from 1.00 to 120.00 dB in a dynamic, magnetic field or a dynamic electromagnetic field having a frequency v of 0.001 to 1000 kHz, the screen factor S (v) is determined from the quotient of the field strength measured at the location of the sink with or without shielding material located between sink and source. Furthermore, the present invention relates to a method for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, wherein a semifinished product according to the invention is used, wherein the plastic layer formed as a coupling layer by injection molding, compression molding, thermal pressing or extrusion molding a three-dimensional plastic structural body is integrally formed, the use of the semifinished product according to the invention for producing a three-dimensionally shaped hybrid component as a component for a vehicle, aircraft, ship, rail vehicle or mechanical engineering, in the energy industry or in construction, and a method for shielding electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields, characterized in that source and / or sink are at least partially surrounded by a semifinished product according to the invention.

In construction and especially in vehicle lightweight components are used to a high degree, which in addition to a low weight must also have high strength and stiffness. Frequently, corresponding lightweight components in a vehicle body serve as crash-relevant structural components, such as a B-pillar, a bumper or a side impact beam. One approach to achieving such lightweight components is to combine different materials together.

Furthermore, materials which have the abovementioned properties are to be provided with further functions, for example with the property of shielding against electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields. Likewise, a trend towards miniaturization can be observed in technology, which in turn places increased demands on electromagnetic compatibility (EMC).

Materials or devices in which shielding metals are combined with plastic layers are already known from the prior art.

US 2007/0134452 A1 For example, discloses a container that can be used in rail vehicles or motor vehicles. It is made of shielding metal and contains a plastic insert. The metal container has an edge at the opening which is bent over to fix the plastic insert.

WO 2008/008693 A2 discloses a cover plate containing a metal sheet and a plastic layer and used to shield electromagnetic radiation.

EP 2 597 740 A1 discloses a material to shield cables through which electrical current flows against electromagnetic radiation. The advantage of this material is that it is flexible and therefore the sheathed cable also remains flexible.

Starting from this prior art, it is an object of the present invention to provide a semi-finished product for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, which in addition to advantageous mechanical properties and a very good shielding effect against electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields. This should make it possible for the manufacturers to produce corresponding hybrid components with a high load-bearing capacity and a high shielding effect significantly more cost-effectively than is possible with the methods of the prior art.

• 0,001 bis 2,1 C,
• 0,001 bis 30,00 Mn,
• 0,001 bis 8,00 Si,
• 0,01 bis 4,00 Al,
• 0,001 bis 1,00 Cr,

These objects are achieved by the inventive thermoformable, platinum or ribbon-shaped semi-finished product for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, the at least one electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields shielding, platinen- or band-shaped metal sheet and at least one thermoplastic, thermoset or elastomeric plastic layer applied in a materially cohesive manner to the metal sheet, wherein the metal sheet has the following composition (in each case in% by weight):

• 0.001 to 2.1 C,
• 0.001 to 30.00 Mn,
• 0.001 to 8.00 Si,
• 0.01 to 4.00 Al,
• 0.001 to 1.00 Cr,

Residual Fe and unavoidable impurities, and the semifinished product has a screen factor S (v) of 1.00 to 120.00 dB in a dynamic, magnetic field or a dynamic electromagnetic field with a frequency v of 0.001 to 1000 kHz, the Umbrella factor S (v) is determined from the quotient of the field strength measured at the location of the sink with or without shielding material located between sink and source.

Furthermore, the objects of the invention are achieved by methods for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, by the use of the semifinished product according to the invention for shielding electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields.

• 0,001 bis 2,1 C,
• 0,001 bis 30,00 Mn,
• 0,001 bis 8,00 Si,
• 0,01 bis 4,00 AI,
• 0,001 bis 1,00 Cr,

The present invention, electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields shielding, platinum or strip-shaped metal sheet has the following composition (in each case in wt .-%):

• 0.001 to 2.1 C,
• 0.001 to 30.00 Mn,
• 0.001 to 8.00 Si,
• 0.01 to 4.00 AI,
• 0.001 to 1.00 Cr,

Residual Fe and unavoidable impurities, up.

Carbon (C) is present in an amount of 0.001 to 2.1 wt%, preferably 0.001 to 0.800 wt%, more preferably 0.002 to 0.700 wt%, most preferably 0.002 to 0.650 wt% ,

Manganese (Mn) is present in an amount of 0.001 to 30.00 wt%, preferably 0.01 to 25.00 wt%, more preferably 0.1 to 23.00 wt%.

Silicon (Si) is in an amount of 0.001 to 8.00 wt .-%, preferably 0.001 to 4.00 wt .-%, particularly preferably 0.01 to 3.5 wt .-%, most preferably 0.02 to 3.4 wt .-%, before.

Aluminum (Al) is in an amount of 0.01 to 4.00 wt .-%, preferably 0.01 to 2.00 wt .-%, particularly preferably 0.02 to 1.8 wt .-%, very particularly preferably 0.02 to 1.6 wt .-%, before.

Chromium (Cr) is present in an amount of 0.001 to 1.00 wt%, preferably 0.01 to 0.5 wt%, more preferably 0.01 to 0.4 wt%.

In addition to the abovementioned alloying elements, the metal sheet used according to the invention may have one or more alloying elements from the following group comprising As, B, Cu, Ni, Mo, Ti, V, S, P and Sn. The present invention therefore preferably relates to the semi-finished product according to the invention, wherein the metal sheet used contains at least one alloying element selected from the group consisting of As, B, Cu, Ni, Mo, Ti, V, S, P and Sn.

• 0 bis 0,01, bevorzugt 0,001 bis 0,004 Gew.-% As und/oder
• 0,001 bis 0,005 Gew.-% B und/oder
• 0,01 bis 0,07 Gew.-% Cu und/oder
• 0 bis 0,5, bevorzugt 0 bis 0,01 Gew.-% Mo und/oder
• 0,001 bis 0,5, bevorzugt 0,001 bis 0,5 Gew.-% Ti und/oder
• 0 bis 0,5, bevorzugt 0,001 bis 0,2 Gew.-% V und/oder
• 0 bis 0,5, bevorzugt 0,001 bis 0,2 Gew.-% P und/oder
• 0,001 bis 0,05 Gew.-% S und/oder
• 0,001 bis 0,01 Gew.-% Sn.

If the said additional alloying elements are present, they are furthermore preferably present in the amounts mentioned below.

• 0 to 0.01, preferably 0.001 to 0.004 wt .-% As and / or
• 0.001 to 0.005 wt .-% B and / or
• 0.01 to 0.07 wt .-% Cu and / or
• 0 to 0.5, preferably 0 to 0.01 wt .-% Mo and / or
• 0.001 to 0.5, preferably 0.001 to 0.5 wt .-% Ti and / or
• 0 to 0.5, preferably 0.001 to 0.2 wt .-% V and / or
• 0 to 0.5, preferably 0.001 to 0.2 wt .-% P and / or
• 0.001 to 0.05 wt .-% S and / or
• 0.001 to 0.01% by weight of Sn.

Unavoidable impurities in the sense of the present invention are, for example, O, N, Nb or Sb.

The production of the metal sheet used according to the invention can be carried out by methods known to the person skilled in the art. In particular, as a metal sheet, a hot strip or a cold strip, more preferably as a coil or as a board, are used.

In a preferred embodiment, the metal sheet used in accordance with the invention has a microstructure comprising 0 to 100% by weight, preferably 5 to 95% by weight, ferrite, 0 to 95% by weight, preferably 0 to 60% by weight, of bainite , 0 to 20 wt .-%, preferably 5 to 20 wt .-% pearlite, 0 to 100 wt .-%, preferably 3 to 35 wt .-%, martensite or up to 100 wt .-% martensite, 0 to 20 Wt .-%, preferably 2 to 15 wt .-%, retained austenite and optionally carbides, the sum being 100% by weight each. These preferred microstructures contribute to the fact that the metal sheet used according to the invention has particularly good mechanical properties, in particular with regard to yield strength, ductility, tensile strength and / or elongation at break. In a preferred embodiment, the metal sheet used according to the invention contains no austenitic structure. In the context of the present invention, this means that the metal sheet used according to the invention has a microstructure which preferably contains less than 8% by weight austenite, particularly preferably less than 5% by weight, very particularly preferably less than 2% by weight , The absence of austenite enables the good shielding properties of the present invention. It has surprisingly been found that the presence of austenite worsens the shielding properties, so that preferably no austenite is present in the metal sheet used according to the invention.

The metal sheet used according to the invention has, for example, a yield strength of 100 to 1900 MPa.

The metal sheet used according to the invention has, for example, a tensile strength of at least 200 MPa, preferably at least 400 MPa, more preferably at least 750 MPa.

The metal sheet used according to the invention has, for example, an elongation at break A80 of 2 to 45%.

More preferably, the metal sheet used according to the invention has a particle size of 2 to 200 .mu.m, preferably 2 to 100 .mu.m, particularly preferably 5 to 30 .mu.m. For example, this grain size preferred according to the invention contributes to improving the magnetic properties.

Instead of a metal sheet of steel material, the semi-finished product according to the invention may also have a metal sheet of another metal, for example of magnesium or aluminum.

The semifinished product according to the invention has at least one thermoplastic, thermoset or elastomeric plastic layer cohesively applied to the metal sheet.

According to the invention, the at least one thermoplastic plastic is preferably selected from the group consisting of polyolefins, polyamides (PA), polycarbonates (PC), thermoplastic polyesters, thermoplastic polyurethanes (PU), polysulfides (PS), polyether ether ketones (PEEK), polyarylene, aromatic polyesters, Polyaramids, polyaramid fibers, heterocyclic polymers, liquid crystal polymers (LCP Liquid Crystalline Polymers), fluoropolymers, perfluorooxyalkanes, polyphenylenes, functionalized variants of said polymers and mixtures thereof.

Examples of polyolefins which can be used according to the invention are selected from the group consisting of acrylonitrile-butadiene-styrenes (ABS), polymethyl (meth) acrylates (PM (M) A), polyethylenes (PE), polypropylenes (PP), polystyrenes (PS), polyvinyl chlorides (PVC) and mixtures thereof.

Examples of polyesters which can be used according to the invention are selected from the group consisting of polyethylene terephthalate (PET), polylactates (PLA) and mixtures thereof.

Examples of polyaramines which can be used according to the invention are selected from the group consisting of poly-m-phenylene isophthalamide (PMI), polyaramid fibers and mixtures thereof.

Examples of heterocyclic polymers which can be used according to the invention are selected from the group consisting of polyimides, polybenzimidazoles, polyetherimides and mixtures thereof.

The present invention therefore preferably relates to the semifinished product according to the invention, wherein the at least one thermoplastic material is selected from the group consisting of polyolefins, polyamides (PA), polycarbonates (PC), thermoplastic polyesters, thermoplastic polyurethanes (PU), polysulfides (PS), polyether ether ketones (PEEK), polyarylene, aromatic polyesters, polyaramides, polyaramid fibers, heterocyclic polymers, liquid crystal polymers (LCP Liquid Crystalline Polymers), fluoropolymers, perfluorooxyalkanes, polyphenylenes, functionalized variants of said polymers and mixtures thereof.

According to the invention, the at least one thermosetting plastic is preferably selected from the group consisting of epoxy resins (EP), urea-formaldehyde resins (UF), Phenol-formaldehyde resins (PF), melamine-formaldehyde resins (MF), melamine / phenol formaldehydes (MPF), thermosetting polyesters (PES), polyurethanes (PUR), unsaturated polyesters (UP), partially crosslinked (bi-stage) thermoset polymers, functionalized Variants of the above polymers and mixtures thereof.

The present invention therefore preferably relates to the semifinished product according to the invention, wherein the at least one thermosetting plastic is selected from the group consisting of epoxy resins (EP), urea-formaldehyde resins (UF), phenol-formaldehyde resins (PF), melamine-formaldehyde resins (MF), melamine / Phenol formaldehydes (MPF), thermosetting polyesters (PES), polyurethanes (PUR), unsaturated polyesters (UP), partially crosslinked (bi-stage) thermosetting polymers, functionalized variants of said polymers and mixtures thereof.

The partially cross-linked (bi-stage) polymers are finally given their final properties by chemically, thermally and / or photolytically initiated polymerization.

According to the invention, the at least one elastomeric plastic selected from the group consisting of natural rubbers (NR), silicone rubbers (SIR), silicone butadiene rubbers (SBR), polyvinyl butyrals (PVB), polyisobutylenes (PIB), isoprene rubbers (IR ), Ethylene vinyl acetates (EVA), ethylene-propylene-diene rubbers (EPDM), ethylene-propylene copolymers (EPM), ethylene-ethyl acrylate copolymers (E / EA), chloroprene rubbers (CR), butadiene rubbers (BR ), Acrylonitrile / methyl methacrylates (A / MMA), butyl rubbers (IIR), styrene-butadiene styrenes (SBS), polyether block amides (PEBA), functionalized variants, and mixtures thereof.

The present invention therefore preferably relates to the semi-finished product according to the invention, wherein the at least one elastomeric plastic is selected from the group consisting of natural rubbers (NR), silicone rubbers (SIR), silicone butadiene rubbers (SBR), polyvinyl butyrals (PVB), polyisobutylenes (PIB), isoprene rubbers (IR), ethylene vinyl acetates (EVA), ethylene-propylene-diene rubbers (EPDM), ethylene-propylene copolymers (EPM), ethylene-ethyl acrylate copolymers (E / EA), chloroprene rubbers (CR), butadiene rubbers (BR), acrylonitrile / methyl methacrylates (A / MMA), butyl rubbers (IIR), styrene-butadiene styrenes (SBS), polyether block amides (PEBA), functionalized variants, and mixtures thereof.

Applicable for all mentioned polymers which can be used according to the invention is that they can likewise be used as mixtures, compounds and polymers which are functionalized by additives.

The cohesive application of the at least one thermoplastic, thermosetting or elastomeric plastic layer on the metal sheet can in principle be carried out according to all methods known to the person skilled in the art. Preferably, the application is carried out by continuous or batch processes, wherein steel strips and / or sheets can be processed. Exemplified by his method using a platen press, a laminator, a calender, a double belt press or a belt coater. Such methods are known per se to the person skilled in the art and in WO 2015/032623 A1beschrieben.

In a preferred embodiment, the present invention relates to the semifinished product according to the invention, wherein the side of the metal sheet, on which the thermoplastic, thermosetting or elastomeric plastic layer is applied, has a surface which improves adhesion of the plastic layer. In order to obtain such a surface, the metal sheet may be subjected to a corresponding surface treatment. The surface treatment may in particular be a plasma treatment, plasma coating, corona treatment or the application of a layer, in particular a primer layer, in a coil coating, dip or drop coating process.

The semifinished product according to the invention has a screen factor S (v) of 1.00 to 120.00 dB, preferably 10.00 to 120.00 dB in a dynamic, magnetic field or a dynamic electromagnetic field with at a frequency v of 0.001 to 1000 kHz, preferably 0.1 to 400 kHz, particularly preferably 0.1 to 200 kHz, on.

bestimmt wird, wobei U₂(v) die in der zweiten Spule induzierte Spannung, I₁(v) der in der ersten Spule fließende Strom und I₁₀(v) der Strom in der ersten Spule und U₂₀(v) die Spannung in der zweiten Spule, jeweils ohne eingebrachte Probe, sind.More preferably, the present invention relates to the semifinished product according to the invention, wherein screen factor S (v) according to the equation of the formula (I) $$S\left(v\right)=20\cdot lO{G}_{10}\left(\frac{I_1\left(v\right)U_{20}\left(v\right)}{U_2\left(v\right)I_{10}\left(v\right)}\right)dB$$

where U ₂ (v) is the voltage induced in the second coil, I ₁ (v) the current flowing in the first coil, and I ₁₀ (v) the current in the first coil and U ₂₀ (v) the voltage in the second coil, each without introduced sample, are.

The shielding factor S (v) is preferably determined by measuring the voltage U ₂ (v) in a second coil induced by a current I ₁ (v) in a first coil while a sample of the shielding monolithic material is located between the first and the second coil and the coils are at a distance of at most 40 mm.

bestimmt, wobei U₂(v) die in der zweiten Spule induzierte Spannung, I₁(v) der in der ersten Spule fließende Strom und I₁₀(v) der Strom in der ersten Spule und U₂₀(v) die Spannung in der zweiten Spule, jeweils ohne eingebrachte Probe, sind.The screen factor S (v) is particularly preferably calculated according to the equation of the formula (I) $$S\left(v\right)=20\cdot lO{G}_{10}\left(\frac{I_1\left(v\right)U_{20}\left(v\right)}{U_2\left(v\right)I_{10}\left(v\right)}\right)\text{dB}$$

where U ₂ (v) is the voltage induced in the second coil, I ₁ (v) is the current flowing in the first coil, and I ₁₀ (v) is the current in the first coil and U ₂₀ (v) is the voltage in the second coil, each without a sample inserted.

1. (A) Bereitstellen einer ersten Spule S1 mit einer ersten Induktivität L1, die mit einem ersten Signalgenerator SG1 und einer Einrichtung zur Strommessung I₁(v) zu einem ersten Stromkreis verbunden ist,
2. (B) Bereitstellen einer zweiten Spule S2 mit einer zweiten Induktivität L2, die mit einer Einrichtung zur Spannungsmessung U₂(v) zu einem zweiten Stromkreis verbunden ist, wobei die Spulen S1 und S2 räumlich so zueinander angeordnet sind, dass sie auf der gleichen Rotationsachse liegen und zwischen ihnen ein Freiraum ausgebildet wird,
3. (C) Einbringen einer Probe des erfindungsgemäßen Halbzeugs in den Freiraum,
4. (D) Generierung einer sinusförmigen Spannung mit einer Frequenz v von 0,001 bis 1000 kHz durch den ersten Signalgenerator SG 1 in der ersten Spule S1,
5. (E) Messen der Stromstärke I₁(v) im ersten Stromkreis,
6. (F) Messen der Spannung U₂(v) im zweiten Stromkreis,
7. (G) Bestimmen des Schirmfaktors S(v) über die Gleichung der Formel (I) $$S\left(v\right)=20\cdot lo{g}_{10}\left(\frac{I_1\left(v\right)U_{20}\left(v\right)}{U_2\left(v\right)I_{10}\left(v\right)}\right)\text{ dB}$$
   
   wobei I₁₀(v) der Strom im ersten Stromkreis und U₂₀(v) die Spannung im zweiten Stromkreis, jeweils ohne eingebrachte Probe, sind.

More preferably, the screening attenuation S (v) of the semifinished product according to the invention is determined by a method, comprising at least the following steps:

1. (A) providing a first coil S1 with a first inductance L1, which is connected to a first signal generator SG1 and a current measuring device I ₁ (v) to a first circuit,
2. (B) providing a second coil S2 with a second inductance L2, which is connected to a device for voltage measurement U ₂ (v) to a second circuit, wherein the coils S1 and S2 are spatially arranged to each other so that they are on the same axis of rotation lie and a free space is formed between them,
3. (C) introducing a sample of the semifinished product according to the invention into the free space,
4. (D) Generation of a sinusoidal voltage with a frequency v of 0.001 to 1000 kHz by the first signal generator SG 1 in the first coil S1,
5. (E) measuring the current intensity I ₁ (v) in the first circuit,
6. (F) measuring the voltage U ₂ (v) in the second circuit,
7. (G) Determining the screen factor S (v) via the equation of the formula (I) $$S\left(v\right)=20\cdot lO{G}_{10}\left(\frac{I_1\left(v\right)U_{20}\left(v\right)}{U_2\left(v\right)I_{10}\left(v\right)}\right)\text{dB}$$
   
   where I ₁₀ (v) is the current in the first circuit and U ₂₀ (v) is the voltage in the second circuit, each without a sample inserted.

The inventively preferred method for determining the screening factor S (v) comprising the steps (A) to (G) is described in detail in the German patent application DE 10 2017 216 985.0 described on 25 September 2017.

The metal sheet used according to the invention can be used uncoated. The metal sheet used according to the invention is used coated in a preferred embodiment. Corresponding coatings, which protect against corrosion in particular, are known per se to a person skilled in the art and are, for example, inorganic coatings such as metals or ceramics or organic coatings based on polymers.

Preference is given to using metallic coatings based on zinc or aluminum or zinc alloys or aluminum alloys in combination with silicon and / or magnesium. The present invention therefore preferably relates to the semi-finished product according to the invention which contains a metal sheet which has a surface coating. The coating can be applied to the metal sheet used according to the invention in general by all methods known to the person skilled in the art, for example electrolytic coating, hot dip method or vapor deposition. The coating can be present on one or both sides. If the metal sheet present in the shielding semifinished product according to the invention is provided with a corresponding surface coating and used, it is advantageously better protected against corrosion.

The at least one metal sheet of the semifinished product according to the invention has, for example, a thickness in the range of 0.1 to 2.5 mm, preferably 0.1 to 1.0 mm, particularly preferably in the range of 0.1 to 0.5 mm.

The cohesive applied to the metal sheet thermoplastic, thermosetting or elastomeric plastic layer, however, may rather be slightly thinner. It has, for example, a thickness in the range of 0.01 to 1.2 mm, preferably 0.05 to 1.0 mm, particularly preferably in the range of 0.05 to 0.4 mm.

In experiments carried out by the applicant, it has been found that a semifinished product according to the invention, whose metal sheet and plastic layer have thicknesses in the stated ranges, is well deep-drawable at room temperature in the Erichsen roasting test. Serving as a coupling layer thermoplastic, thermosetting or elastomeric plastic layer flows during deep drawing of the semifinished product according to the invention with the metal sheet and does not lose its liability.

1. 1. Platinen- oder bandförmiges Halbzeug konfektionieren (Zuschneiden);
2. 2. Zugeschnittenes Halbzeug zu einem Umformwerkzeug mit integriertem Spritzgießaggregat transportieren und einlegen;
3. 3. Umformen und Hinterspritzen des Halbzeugzuschnitts in einem Schritt.

The function of the thermoplastic or thermosetting plastic layer (coupling layer) of the semifinished product according to the invention is that it can be reliably bonded with a large number of other plastics without application of adhesive. In the injection molding process, for example, the energy of the plastic melt is used to activate the surface of the coupling layer and produce the material bond. After cooling the melt is a perfect bond between the coupling layer and the molded plastic. The molded plastic may not only be thermoplastic material but also thermoset plastic and / or a plastic material in the field of elastomers. It continues possible to additionally activate the coupling layer surface by plasma or corona pretreatment before the injection molding process in order to expand the range of usable plastics. The semifinished product according to the invention makes it possible to considerably reduce the work steps to be carried out at the location of an automobile manufacturer or component supplier for producing a three-dimensionally shaped hybrid component. For example, the automobile manufacturer or component supplier with the semifinished product according to the invention has, in particular, the possibility of producing a three-dimensionally shaped hybrid component by the following process steps:

1. 1. Assemble blank or ribbon-shaped semi-finished products (cutting);
2. 2. Transport cut semi-finished product to form a forming tool with integrated injection molding unit and insert it;
3. 3. Forming and injection molding of the semi-finished blank in one step.

An advantageous embodiment of the semifinished product according to the invention is characterized in that the plastic layer (coupling layer) does not completely cover the side of the metal sheet on which it is applied, but partially covers it. This embodiment is particularly useful if the hybrid component to be produced, for example, only partially has a strength and / or stiffness-increasing rib structure made of plastic. One or more larger surface areas of the metal sheet, which should not have a rib structure after completion of the hybrid component, can thus remain uncoated during the coating of the metal sheet with the at least one thermoplastic or duroplastic plastic layer (coupling layer). This saves material costs and contributes to an optimized weight saving with sufficient strength or stiffness properties and good shielding effect.

A further advantageous embodiment of the semifinished product according to the invention is that the thermoplastic, thermosetting or elastomeric plastic layer is made double, wherein between the two plastic layers, a, in particular thermoplastic, foam layer is arranged. It has been found that the intermediate arrangement of a, in particular thermoplastic, foam layer can contribute significantly to the weight reduction of the hybrid component with constant strength and rigidity.

A further advantageous embodiment of the semi-finished product according to the invention is that in each case a thermoplastic, thermoset or elastomeric plastic layer is present on both sides of the metal sheet.

According to a further advantageous embodiment, the plastic layer (coupling layer) of the semifinished product according to the invention is partially coated with at least one organic sheet. As a result, the strength and rigidity of the hybrid component to be produced can be significantly improved while the overall weight remains constant or even reduced.

Alternatively or additionally, according to a further embodiment of the semifinished product according to the invention, its metal sheet may also be coated with at least one organic sheet on its side facing away from the plastic layer (coupling layer). This refinement also allows the strength and rigidity of the hybrid component to be produced to be significantly increased while the overall weight remains constant or even reduced, and with the same or even enhanced shielding effect. In this case, according to a further embodiment, the organic sheet may be coated on its side facing away from the metal sheet with at least one second metal sheet. From such a semi-finished product, it is possible to produce particularly lightweight and at the same time very rigid and stiff hybrid components with a correspondingly shielding effect, in particular if the organic sheet contains carbon fibers according to a preferred embodiment. In addition, in another embodiment, the second metal sheet may be coated on the outside with a thermoplastic or thermosetting plastic layer, which is also formed as a coupling layer for cohesive, adhesive-free connection at least one made of plastic or manufactured structural body. From a semi-finished product designed in accordance with the invention, it is advantageously possible to produce hybrid components without an application of adhesive, which have structural bodies produced on both sides of plastic, in particular ribbed bodies.

Another advantageous embodiment of the semifinished product according to the invention is that the metal sheet is coated on its side facing away from the plastic layer with a second thermoplastic or thermosetting plastic layer, which is also formed as a coupling layer for cohesive, adhesive-free connection at least one made of plastic or manufactured structural body. Also from such a semifinished product according to the invention can be produced without application of adhesive hybrid components having both sides made of plastic structural body, in particular rib body. In this case, the second plastic layer (coupling layer), the surface of the metal sheet on which it is applied, cover the whole area or partially. The partial coating of the metal sheet by the second plastic layer is expedient, for example, if the hybrid component to be produced on the corresponding side of the metal sheet only partially Has rib structure made of plastic, which is adhesively bonded without adhesive over the partial coupling layer to the metal sheet.

A further advantageous embodiment of the semifinished product according to the invention is that the second plastic layer is coated on its side facing away from the metal sheet with a second metal sheet. The second metal sheet may be coated in a further embodiment on its side facing away from the second plastic layer side with a third thermoplastic or thermosetting plastic layer as a coupling layer. Even with semi-finished products designed in accordance with the invention, lightweight hybrid components with high strength and rigidity and a corresponding shielding effect can be produced inexpensively. The same applies to a further embodiment of the semifinished product according to the invention, in which the second plastic layer is completely or partially coated with at least one organic sheet.

According to a further embodiment of the semifinished product according to the invention, the respective plastic layer serving as a coupling layer is provided with a peelable protective film. The protective film protects the surface of the coupling layer during the transport of the semifinished product and possibly also during the forming of the semifinished product. As a result, prior to the molding of plastic structures, such as plastic ribs, a complex cleaning of the coupling layer surface of contaminants such as oil or grease omitted. In addition, the protective film as a drawing film can improve the sliding properties of the semifinished product during forming.

The semi-finished product according to the invention is preferably formed as a flat product. It can be processed by means of a platen press in a static process, an interval heating press in a batch process or in a continuous process in a laminating plant, for example a double belt press. The process parameters are set in each case specifically for the semi-finished product to be produced. Depending on the semifinished product variant, panels can be cut from this, or the band-shaped semi-finished product can be rolled up into a coil.

The present invention also relates to a method for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, wherein a semi-finished product according to the invention is used, wherein the three-dimensional plastic structural body (plastic structural body) is adhesively bonded to the plastic layer formed as a coupling layer by injection molding, compression molding, extruding or thermal pressing is molded.

As already stated, the semifinished product according to the invention makes it possible to produce a three-dimensionally shaped hybrid component made of metal and plastic with a structural body, preferably a ribbed body, of plastic without application of adhesive. This significantly simplifies the production of the hybrid component.

A preferred embodiment of the method according to the invention is that the semifinished product is formed into a three-dimensional shape prior to molding of the structural body. The forming is preferably carried out by deep drawing or roll forming.

A further advantageous embodiment of the method according to the invention is characterized in that the semifinished product by means of a forming tool having at least one integrated Spritzgießkavität and at least one opening into the Spritzgießkavität injection molding is reshaped. This refinement offers the possibility of reducing the number of process steps for producing the hybrid component, in that the forming of the semifinished product or semifinished product blank and the injection molding of the coupling layer for producing the structural body, preferably fin body, are carried out in the same process step.

Another advantageous embodiment of the method according to the invention is characterized in that the semifinished product by means of a forming tool, which has a profile with at least one integrated cavity for pressing and three-dimensional shapes of a plastic material is reshaped. This variant also offers the possibility of reducing the number of process steps for producing the hybrid component, in that the forming of the semifinished product or semifinished product blank and the pressing of the plastic material to produce the structural body, preferably ribbed body, are carried out on the coupling layer in the same process step.

A further variant of the method according to the invention is that the semi-finished product is formed by roll forming, during or after the forming of the semifinished product, a rotatable, wheel-shaped tool is used for molding the structural body, and the tool with a profile having at least one cavity for pressing and Three-dimensional shapes of a plastic material is provided. With this embodiment of the method, in particular designed as a profile carrier hybrid components of the type mentioned can be effectively produced in mass production.

According to a further embodiment of the method according to the invention, at least one integral flange is formed on the hybrid component, which has the thermoplastic layer formed as a coupling layer, wherein the plastic layer another as a metal / plastic composite executed hybrid component or an organic sheet is added by welding. In this way, for example, designed as half-shells hybrid components can be inexpensively assembled into a hollow channel or closed profile. The same applies with regard to a combination of a hybrid component according to the invention with an organic sheet which delimits the hollow channel or the closed profile. The welded connection of the hybrid components designed as half shells or of the organic sheet with a single hybrid component can be produced, for example, by friction welding, spot welding, ultrasonic welding, etc.

According to a third teaching of the present invention, the semifinished product according to the invention is advantageously used for producing a three-dimensionally shaped hybrid component as a component for a vehicle, aircraft, ship or building. Advantages arise namely by the semifinished product according to the invention everywhere, where in addition to a weight saving and high shielding against electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields is required and this hybrid components of the type mentioned in as few process steps to be produced ,

The present invention therefore also relates to the use of the semifinished product according to the invention for producing a three-dimensionally shaped hybrid component as a component for a vehicle, aircraft, ship, rail vehicle or in mechanical engineering, in the energy industry or in construction.

Furthermore, the present invention also relates to a method for shielding electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields, characterized in that source and / or sink are at least partially surrounded by a semifinished product according to the invention or a component formed therefrom ,

In this method according to the invention, the source and / or sink of the electromagnetic radiation, of the dynamic or static electrical and / or dynamic or static magnetic fields is at least partially surrounded by the semifinished product according to the invention or a component formed therefrom. A partial surrounding is useful or necessary, for example, if the source and / or sink must be accessible during operation, for example, by supply and / or discharge and / or operation. According to the invention it is also possible that the source and / or sink is completely surrounded by the semifinished product according to the invention or a component formed therefrom. Details and preferred embodiments, which have been mentioned to the semifinished product according to the invention, should also be applied here accordingly.

If the semi-finished product according to the invention or a component formed therefrom is used for shielding electromagnetic radiation, it has, for example, a thickness of 0.10 to 4.0 mm, preferably 0.12 to 2.2 mm, particularly preferably 0.12 to 1.0 mm, up.

The present invention also relates to the use of the semifinished product according to the invention or of a component formed therefrom for shielding electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields.

Electromagnetic, dynamic or static electrical and / or dynamic or static magnetic fields are intentionally or unwillingly generated by the use and operation of certain magnetic, electrical or electronic devices.

In a particular embodiment, the present invention relates to the use according to the invention, wherein in addition a high mechanical strength of the semifinished product or of a component formed therefrom is given, for example expressed by a yield strength of at least 200 MPa, preferably at least 400 MPa, more preferably at least 750 MPa. A particular advantage of the present invention is therefore that a material can be provided which according to the invention preferably also has good mechanical properties in addition to a high shielding effect.

Preferably, the present invention relates to the use according to the invention, wherein buildings, in particular safety-related buildings, rooms, laboratories, production facilities, server cabinets, control cabinets, plug connections, holders and housings, for example for electrical machines power electronics, computers, communications electronics, alarm systems, security technology, fire and gas detectors , Protective covers, charging stations, kitchen appliances, medical devices, electronic devices, preferably in automobiles, electronic components, radios, magnetic applications, such as permanent magnets, electronic components and / or batteries, such as non-rechargeable batteries or accumulators, shielded or the shielding material as Ceiling and / or wall panels, as floor coverings, as cable ducts, in the measuring technology is used.

The invention will be explained in more detail below with reference to embodiments and illustrative drawing:

characters

1

Metallblech

2

Kunststoffschicht

3

Kunststoffstrukturkörper

The in the 1 . 2 and 3 Reference numerals used have the following meanings:

1

metal sheet

2

Plastic layer

3

Plastic structure body

• 1 shows an inventive thermoformable, platinum or strip-shaped semi-finished product for producing a three-dimensionally shaped hybrid component in the metal / plastic composite.
• 2 shows a three-dimensionally shaped hybrid component according to the invention in the metal / plastic composite.
• 3 shows an inventive three-dimensionally shaped hybrid component in the metal / plastic composite with applied plastic structural body.

Industrial Applicability

The semifinished product according to the invention combines good mechanical characteristics and a high degree of shielding against electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields, so that advantageous three-dimensionally shaped hybrid components can be produced as components for a vehicle, aircraft, ship or building.

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

• US 2007/0134452 A1 [0005]
• WO 2008/008693 A2 [0006]
• EP 2597740 A1 [0007]
• WO 2015/032623 [0041]
• DE 102017216985 [0048]

Claims (17)

Deep-drawing, platinum or strip-shaped semi-finished product for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, the at least one electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields shielding, platinen- or band-shaped metal sheet and at least one on the metal sheet materially applied thermoplastic, thermosetting or elastomeric plastic layer, characterized in that the metal sheet has the following composition (each in wt .-%) - 0.001 to 2.1 C, - 0.001 to 30.00 Mn, - 0.001 to 8.00 Si - 0.01 to 4.00 Al, - 0.001 to 1.00 Cr, remainder Fe and unavoidable impurities, and the semi-finished product a screen factor S (v) of 1.00 to 120.00 dB in a dynamic, magnetic field or a dynamic, electromagnetic field with a frequency v of 0.001 to 1000 kHz, wherein the screen factor S (v) from the quotient de r field strength measured at the location of the sink with or without shielding material located between sink and source is determined. Semi-finished product Claim 1 , characterized in that the screen factor S (v) of the semifinished product is detected by detecting the voltage U2 (v) in a second coil, which is induced by a current I1 (v) in a first coil, while a sample of the semifinished product is between the first and the second coil is located and the coils are at a distance of at most 40 mm, is determined. Semi-finished product Claim 1 or 2 , characterized in that the side of the metal sheet, on which the plastic layer is applied, has a surface which improves the adhesion of the plastic layer. Semi-finished product after one of Claims 1 to 3 , characterized in that the plastic layer is formed as a coupling layer for cohesive, adhesive-free connection of at least one plastic body produced or produced structural body. Semi-finished product after one of Claims 1 to 4 , characterized in that the metal sheet additionally contains at least one alloying element selected from the group consisting of As, B, Cu, Ni, Mo, Ti, V, S, P and Sn. Semi-finished product after one of Claims 1 to 5 , characterized in that the screen factor S (v) according to the equation of the formula (I) $$S\left(v\right)=20\cdot lO{G}_{10}\left(\frac{I_1\left(v\right)U_{20}\left(v\right)}{U_2\left(v\right)I_{10}\left(v\right)}\right)dB$$

where U ₂ (v) is the voltage induced in the second coil, I ₁ (v) the current flowing in the first coil, and I ₁₀ (v) the current in the first coil and U ₂₀ (v) the voltage in the second coil, each without introduced sample, are. Semi-finished product after one of Claims 1 to 6 , characterized in that the metal sheet contains a microstructure containing 0 to 100 wt .-% ferrite, 0 to 95 wt .-% bainite, 0 to 20 wt .-% pearlite, 0 to 100 wt .-% martensite or up to 100 wt % Martensite, 0 to 20% by weight of retained austenite and optionally carbides, the sum each giving 100% by weight. Semi-finished product after one of Claims 1 to 7 , characterized in that the at least one thermoplastic material is selected from the group consisting of polyolefins, polyamides (PA), polycarbonates (PC), thermoplastic polyesters, thermoplastic polyurethanes (PU), polysulfides (PS), polyether ether ketones (PEEK), polyarylene, aromatic polyesters, polyaramides, polyaramid fibers, heterocyclic polymers, liquid crystal polymers (LCP Liquid Crystalline Polymers), fluoropolymers, perfluorooxyalkanes, polyphenylenes, functionalized variants of said polymers and mixtures thereof. Semi-finished product after one of Claims 1 to 7 , characterized in that the at least one thermosetting plastic is selected from the group consisting of epoxy resins (EP), urea-formaldehyde resins (UF), phenol-formaldehyde resins (PF), melamine-formaldehyde resins (MF), melamine / phenol formaldehydes (MPF ), thermosetting polyesters (PES), polyurethanes (PUR), unsaturated polyesters (UP), partially crosslinked (bi-stage) thermosetting polymers, functionalized variants of said polymers and mixtures thereof. Semi-finished product after one of Claims 1 to 7 , characterized in that the at least one elastomeric plastic is selected from the group consisting of natural rubbers (NR), silicone rubbers (SIR), silicone butadiene rubbers (SBR), polyvinyl butyrals (PVB), polyisobutylenes (PIB), isoprene Rubbers (IR), ethylene vinyl acetates (EVA), ethylene-propylene-diene rubbers (EPDM), ethylene-propylene copolymers (EPM), ethylene-ethyl acrylate copolymers (E / EA), chloroprene rubbers (CR), butadiene rubbers (BR), acrylonitrile / methyl methacrylates (A / MMA), butyl rubbers (IIR), styrene-butadiene styrenes (SBS), polyether block amides (PEBA), functionalized Variants and mixtures thereof. Semi-finished product after one of Claims 1 to 10 , characterized in that the plastic layer, the side of the metal sheet on which it is applied, partially or completely covered. Semi-finished product after one of Claims 1 to 11 , characterized in that the thermoplastic, thermosetting or elastomeric plastic layer is made double, wherein between the two plastic layers, a thermoplastic foam layer is arranged. A method for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, characterized by the use of a semifinished product according to one of Claims 1 to 12 in which a three-dimensional plastic structural body is integrally formed on the plastic layer in the form of a coupling layer by injection molding, compression molding, thermal pressing or extruding. Use of the semifinished product according to one of Claims 1 to 12 for producing a three-dimensionally shaped hybrid component as a component for a vehicle, aircraft, ship, rail vehicle or in mechanical engineering, in the energy industry or in construction. A method for shielding electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields, characterized in that source and / or sink at least partially with a semifinished product according to one of Claims 1 to 12 or a component formed therefrom. Use of the semifinished product according to one of Claims 1 to 12 or a component formed therefrom for shielding electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields. Use after Claim 16 , characterized in that buildings, in particular security-relevant buildings, rooms, laboratories, production facilities, server cabinets, control cabinets, plug connections, holders and housings, for example for electrical machines, power electronics, computers, communications electronics, alarm systems, security technology, fire and gas detectors, protective covers, charging stations , Kitchen appliances, medical devices, electronic devices, preferably in automobiles, electronic components, radios, magnetic applications, for example, permanent magnets, electronic components and / or batteries, such as non-rechargeable batteries or accumulators, shielded or the shielding material as ceiling and / or or wall panels, as floor coverings, as cable ducts, in the measuring technology is used.

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