EP1282499A1

EP1282499A1 - Profile composite component and method for the production thereof

Info

Publication number: EP1282499A1
Application number: EP01980211A
Authority: EP
Inventors: Joachim Wagenblast
Original assignee: Bayer AG
Current assignee: Bayer AG
Priority date: 2000-05-08
Filing date: 2001-04-25
Publication date: 2003-02-12
Also published as: BR0110640A; US20030152745A1; AU2002212112A1; CZ20023702A3; DE10022360A1; CA2408241A1; TW519561B; MXPA02010963A; JP2004501802A; KR20020091276A; CN1222400C; WO2002002292A1; CN1427758A; PL358325A1; AR028027A1

Abstract

The invention relates to a composite component consisting of two or more profiles (1) and (2) and to a method for the production thereof. According to the invention, at least one profile (1), with one free end, abuts against the second profile (2) or is inserted into the second profile (2). The invention is characterized in that reinforcing elements (3, 3'; 6, 6'; 23; 25; 21), which form a positive engagement with profiles (1) and (2), are provided in the area of the junction (10) of profiles (1) and (2), and profiles (1) and (2) are interconnected by a thermoplastic material that is sprayed or shrunk on in the area of the junction (10).

Description

Composite component and method for its production

The invention relates to a composite component from two or more profiles and a method for its production, in which at least one profile with a free

End adjoins the second profile or is immersed in the second profile, characterized in that reinforcing elements are attached in the area of the connection point of the profiles, which form a positive connection with the profiles, and that the profiles are joined together by thermoplastic material which is injection-molded or shrunk on in the area of the connection point are connected.

The invention relates in particular to a method for joining profiles and plates by creating high-strength and highly rigid composite components, in particular in a plastic-metal hybrid construction, the joining of the semi-finished products and the production of the composite components being achieved simultaneously by a shaping process of thermoplastic molding compositions.

The invention also relates to a method for connecting semi-finished products by creating highly resilient joining areas in hybrid construction.

The process produces composite components that consist of high-strength and high-rigidity components such as Made of steel or composites, which are joined with the help of a thermoplastic, held in position and additionally supported in the form of ribs or solid walls.

High-strength connections of heavy-duty beams, profiles, plates, etc. can often be found in vehicle or mechanical engineering. Beams made of steel or aluminum are predominantly used, which are welded or glued together in the joining areas. To further stiffen the connection points, also referred to below as nodes, struts are integrated or cast nodes, eg aluminum die-cast, are used. Another option is the use of semi- made of composite (long fiber reinforced plastic). These are usually connected to each other by laminating node elements, which also consist of composites.

These procedures, which are common in practice, have the disadvantage that the joining processes are time-consuming and only allow limited dimensional accuracy and reproducibility in series production. If struts are used to additionally stiffen the node elements, these must be made thick-walled (1 to 3 mm) to prevent failure due to buckling or kinking. Usual wall thicknesses of sheets used in the automotive industry are in

Car construction at 0.7 to 1.2 mm. This increases the weight of the component, which runs counter to the efforts of the designers, particularly in vehicle construction.

The invention is therefore based on the object of creating joining methods with nodes of the type mentioned at the outset, which both enable high-strength and highly rigid connections of supports and plates and also allow economical joining of semi-finished products and component components to components. In addition, the manufacture of the composite components should take place with high dimensional accuracy and reproducibility. A particular task is the collapse of thin-walled profiles with a wall thickness of 0.5 to, due to the injection pressure

Avoid 1 mm when processing profiles in injection molding machines.

This object is achieved according to the invention in that parts made of high-strength materials are used to connect the semifinished products or component components and to stiffen the composite components, which are arranged in a form-fitting manner in the node area. The knot area is then provided with a thermoplastic component that holds all the individual parts together and prevents premature bulging or buckling of the high-strength individual parts in the knot area.

The invention relates to a composite component made of two or more profiles, in which at least one profile adjoins the second profile with a free end or immersed in a second profile, characterized in that reinforcement elements are attached in the area of the connection point of the profiles, which form a positive fit with the profiles, and that the profiles are connected to one another by thermoplastic material which is injection-molded or shrunk on in the area of the connection point.

The reinforcing elements are e.g. Sheets or die-cast parts made of high-strength material. The high-strength materials can be steel, aluminum, magnesium, ceramics, thermosets or long-fiber reinforced plastics, composites or plastics reinforced with technical textiles.

An unreinforced or reinforced or filled plastic, e.g. based on polyamide (PA), polyester, especially polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyolefin, especially polypropylene (PP), polyethylene (PE), styrene-acrylonitrile copolymer, in particular

Acrylonitrile-styrene-butadiene copolymer (ABS), polycarbonate (PC), polypropylene oxide (PPO), (PSO), polyphenylene sulfide (PPS), polyimide (PI), (PEEK), polyketone syndiotactic polystyrene (PS) or from a possible mixture these plastics exist.

Profiles in the sense of the invention are, for example, open or closed profiles made of plastic or metal (preferably metal, e.g. steel, aluminum, magnesium) with any cross section. Closed profiles with a round or rectangular cross section or open U-profiles are preferred. The profiles preferably have a wall thickness of 0.3 to 1.5 mm, particularly preferably 0.5 to 1.2 mm.

The reinforcement elements are used as highly rigid connecting components in the form of, for example, clips, rings and half-shells, the shape of which is adapted to the profiles (semi-finished products) and component components to be joined and in particular with the aid of struts and / or preferably with further support plates are additionally supported. You will see the profiles and profiles to be joined other component parts. The reinforcement elements serve to reinforce and stiffen the connection point and are designed so that they form-fit with the semi-finished products and component components to be joined.

In a preferred form of the composite component, the reinforcement elements are provided with additional supporting walls, which make it more difficult, particularly in the case of an abutting profile, to kink the connection point.

A composite component is particularly preferred in which a one-piece reinforcing element is provided at the connection point of the profiles, into which the profiles in front of the

Injection molding of the thermoplastic is inserted or inserted.

The thermoplastic component is arranged as a connecting material with the aid of a shaping process in such a way that it holds the components (profiles and or plates) which are butting against one another in a form-fitting manner but which are otherwise loosely connected as well as the reinforcing elements themselves in position. This can be done by partially or completely enclosing the reinforcing elements.

The power transmission from one component to the other takes place via the high-strength components of the reinforcing elements. By optionally integrally formed ribs or by filling gaps - which e.g. are formed by individual support plates - with the thermoplastic component an additional increase in the strength of the composite components is achieved, since bulging or kinking of struts and support walls of the reinforcing elements only occurs with higher loads.

A composite component has proven to be particularly advantageous in which openings and bores through which the thermoplastic is provided are provided in the profiles and / or in the reinforcing elements at points lying one above the other

Plastic protrudes through and to which the thermoplastic is anchored. Additionally or alternatively, in a further preferred variant of the composite component in the profiles and / or in the reinforcing elements, deformations, in particular beads or beads, can be provided at which the thermoplastic is anchored.

A preferred composite component is particularly advantageous, in which the reinforcing elements are formed in one piece with at least one of the profiles, and in which the profiles form a positive fit with one another.

For example, the interlocking profiles are pre-shaped so that they have matching tongue and groove combinations or projections that ensure a positive fit.

A profile can additionally have a reinforcement in the area of the connection point in the form of the preferred materials for the reinforcement elements or have a higher wall thickness.

A method for connecting profiles (semi-finished products or component components) was also found by producing a composite component during the

Joining process, which is made up of at least two different materials. One material component consists of a thermoplastic, while the other component is usually made of a high-strength material.

Another object of the invention is therefore a method for producing a composite component according to the invention, characterized in that two or more profiles are inserted or inserted into reinforcing elements or clasped by reinforcing elements to form a detachable connection point, and then the connection point in an injection molding tool made of thermoplastic plastic is wholly or partially encapsulated, the profiles with the

Reinforcing elements are connected. A method is preferred in which open profiles are used and reinforcing struts are produced in the open profiles when the thermoplastic is molded on.

In order to improve the rigidity of open profiles, additional reinforcing struts are produced in the area of the connection point when the thermoplastic is molded on.

An alternative manufacturing method for manufacturing an inventive

Composite component is characterized in that two or more profiles are inserted or inserted into reinforcing elements or clasped by reinforcing elements to form a detachable connection point, and that the connection point is then wholly or partially surrounded with one or more molded parts made of shrinkable thermoplastic, and the profiles with the reinforcing elements are then connected by heat treatment of the fittings.

A particularly preferred method is characterized in that, in the profiles and / or in the reinforcing elements, deformations, in particular beads or beads, and / or openings or bores at certain points in the profiles and / or the reinforcing elements, before being folded or pushed in, are attached so that they lie one above the other when the profiles and / or the reinforcing elements are folded or pushed in before the thermoplastic is attached.

Since the joining process is achieved by thermally deforming the thermoplastic component, the shrinkage of the thermoplastic material can be used to build up stresses that ensure a permanent and firm bond in the area of the connection point of the profiles. In addition, further additional elements can be integrated into the composite component, which fulfill mechanical functions such as, for example, supporting additional plates or supports, attaching parts to be retrofitted or accommodating further components. On the one hand, these integrated elements can be made of high-strength elements with the help of form-fitting inserted

Materials and on the other hand by molding beads, recesses or screw domes using thermoplastic components.

The production of the composite component and thus also the type of implementation of the joining process can take place in different ways. The conceivable methods differ primarily in the application of the thermoplastic component:

Joining by injection molding

In the joining process using injection molding, the component components to be joined: profiles or profiles and plates and the reinforcing elements are first inserted into an injection molding tool. The injection mold is then closed and the thermoplastic is injected. Since the plastic material is poured into the injection mold in liquid form, it can enclose the inserts on all sides and thereby secure the form fit already achieved through the design of the reinforcing elements. With the help of breakthroughs in the semi-finished products or component components to be joined and / or the reinforcing elements, a connection of the thermoplastic component in the form of rivet heads can also be achieved, in particular in the area of overlapping breakthroughs in the profiles and reinforcing elements. With this type of connection, it is not necessary to completely encase the node area.

To prevent plastic melt from entering the interior of the profiles when joining hollow profiles, for example, they can be fixed on the end faces with a cover (e.g. with welding plate or with a sheet-reinforced plastic cap) or temporarily with the help of movable cores attached in the tool be closed. If high injection pressures are used in the injection molding process, collapse of the hollow profiles is prevented by also using moving cores in the injection molding tool or rib structures, double T-pieces or other reinforcements, eg made of metal foams, remaining in the hollow profile.

Joining by shrinking on thermoplastic elements

The procedure for this method variant does not fundamentally differ from the previous method using injection molding. Here too, the semi-finished products or component components to be joined and the reinforcing elements are joined together in a form-fitting manner but in a loose bond. Subsequently, however, the cohesion of these individual parts is secured with a connecting element made of thermoplastic plastic, which is placed or snapped over the knot in the joining area. The thermoplastic connecting element used was previously stretched and is now shrunk onto the semi-finished products or component components and reinforcing elements in the node area to build up a non-positive support for the form-fitting reinforcing elements.

Combination of different joining and or forming processes

There are further options for joining the semi-finished products or component components and reinforcing elements when the two methods described above are combined.

In addition, it can also be advantageous that clips, shells or the like made of thermoplastics with and without reinforcements (for example from inserted sheet metal) are first plugged on and subsequently completed by means of injection molding, gluing or welding to form the connecting elements encompassing the node area on all sides. Furthermore, the manufacture of the reinforcement elements as well as the production of the connecting element and the joining process can be combined into one process step. If the reinforcing elements consist, for example, of sheet metal, they can be shaped into their final shape during the injection molding process. For this purpose, flat or already to a certain extent preformed metal sheets with the components to be joined are placed in the injection mold. By moving the two halves of the tool together and applying the required closing force, the reinforcement plates are deformed in such a way that they form-fit around the components. Finally, the components to be joined and the reinforcing elements are connected by injecting and cooling the plastic melt.

The advantages achieved with the invention can be summarized as follows:

The invention enables the construction of permanently high strength and high stiff nodes and composite components using simply designed semi-finished products

It is possible to join several joints at the same time within one injection mold.

The manufacturing process ensures high dimensional accuracy and reproducibility in the

Series production of components with joints.

The integration of additional mechanical or other functions in naturally high-strength and high-stiff node areas is made possible.

The design of composite components can be optimized in terms of cost and weight

Another object of the invention is the use of the composite components according to the invention in a corresponding design as a construction element for machines Vehicle and components of all kinds, in particular for motor vehicles, for electronic items, household items and for building supplies.

Particularly suitable applications of the composite component are structural parts for motor vehicles, in particular doors, bumpers, beams, front and rear parts for cars,

Door sill support frame, instrument panel support, tailgate support, roof frame and decorative elements, which combine increased strength with other material properties.

The invention is explained in more detail below with reference to figures, without the invention being restricted thereby in detail.

Show it:

Fig.l a composite component with two reinforcing elements 3, 3 'for connecting two rectangular profiles connected by a molded thermoplastic

Fig. 2 shows a composite component similar to Fig. 1 with an additional reinforcing edge

3 shows a composite component similar to FIG. 1 with a connection by shrink-fit thermoplastic molded parts 4, 5

4 shows a composite component similar to FIG. 1 but without lateral rib structures on the thermoplastic and with a one-piece reinforcing element 3

5 shows a composite component similar to FIG. 1 with fully encapsulated reinforcing elements 3, 3 '

6 shows the side view of a composite component with two reinforcing elements 3, 3 'with a flange 63 at the end of the profile 2 and fully with

Plastic overmolded connection point 10

7 shows the cross section through a composite component according to FIG. 6 along the line A-A in FIG. 6

8 shows the individual representation of the reinforcing elements 3, 3 'for a composite component according to FIG. 6

9 is a top view of the reinforcing elements 3, 3 'according to FIG. 8

10 shows the side view of the reinforcing elements 3, 3 'according to FIG. 8 Fig. 11 is a composite component from three profiles 1, 2, 8 in which the profiles 1 and

8 adjoin profile 2

Fig. 12, the composite component of FIG. 11 from the back

13, 14 differently shaped reinforcing elements 30, 136 for the composite component according to FIG. 11

15 shows a composite component made of thin-walled hollow profiles 1, 2 similar to FIG. 4 but with two reinforcing elements 3, 3 '

16 shows a composite component comprising a box section 161 and a U section 162 with reinforcing elements 21, 23, 25 integrated in the U section

FIG. 17 individual representation of the U-profile from FIG. 16

18 individual representation of the box profile from FIG. 16

19 shows a cross member for a motor vehicle instrument panel as an example of a complex composite component

20 shows the longitudinal section through the profile 9 of the cross member according to FIG. 19 along the line A-A in FIG. 19

Fig. 21 is the view of the cross member according to Fig. 19 without extrusion molding of the profiles

22 shows the door frame structure of a motor vehicle as a further example of a complex composite component Fig. 23 shows the view of the door frame structure without plastic injection molding

profiles

24 shows the tailgate frame for a motor vehicle as a further example of a complex composite component

Examples

Connections of solid solid and / or thick-walled hollow profiles: Figures 1 to 10

example 1

The composite components shown in FIGS. 1 to 5 are the connection of two rectangular components (profiles) 1 and 2, which are held together in a form-fitting manner via high-strength and highly rigid reinforcing elements 3 and 3 'and with the aid of two connections 4 and 5 be firmly connected and supported from thermoplastic. FIGS. 6 and 7 show how the components and reinforcing elements to be connected are held together and supported by a thermoplastic plastic which surrounds the connection point 10

4 realized.

In all of the representations of FIGS. 1 to 10, the mutual support of the profiles 1 and 2 takes place by means of support walls 31 integrated into the reinforcing elements 3, 3 '. This prevents the profile 1 from bending sideways against the profile 2. The

Contour of profiles 1 and 2 is encompassed by walls 32 of reinforcing elements 3 and 3 ', respectively. This creates a positive connection between the profiles 1 and 2 to be joined and the reinforcing elements 3, 3 '.

If thin-walled hollow profiles are joined using injection molding, care must be taken to ensure that the hollow profiles do not fail or collapse due to the relatively high injection pressure when the plastic melt is injected into the injection mold. To prevent this, there are two fundamentally different solution variants. On the one hand, the hollow profiles can be supported from the inside with the help of cores and on the other hand there is the possibility of constructive Design of the composite component to limit the effect of the spray pressure on the reinforcing elements.

1 shows a composite component with two reinforcing elements 3, 3 'for connecting two rectangular profiles 1, 2, which are formed by an injection-molded thermoplastic

4 can be connected.

FIG. 2 shows a composite component similar to FIG. 1, in which the reinforcement elements are provided with an additional reinforcement edge in the region of the support wall.

4, the reinforcing element 3 consists of one part.

In the composite component according to FIGS. 1 to 3, the profiles 1 and 2 to be joined are inserted or inserted into the reinforcing elements 3, 3 ¹ and inserted into an injection mold. The injection molding of the thermoplastic component 4 creates the connecting elements 4 and 5, which hold the reinforcing elements 3, 3 ′ together via the simultaneously created walls 42 and the rib structure 41 made of thermoplastic material.

In the case of a composite component according to FIG. 3, the connecting elements 4 and 5 can also be preformed separately. These are then stretched before the joining process and then attached to the support walls 31. Subsequent heating causes the thermoplastic parts 4, 5 to be firmly shrunk onto the reinforcing elements 3, 3 ¹ in this variant. In the composite components according to FIGS. 1 to 3, the two slightly inwardly curved support walls 31 are supported by the rib structure 41. This prevents premature bulging or kinking of the support walls 31. In the composite components according to FIGS. 4 and 5, this task is performed by the wall 43 made of thermoplastic material and arranged between the support walls 31. In the composite components according to FIGS. 1 and 4, the thermoplastic 4 or 5 is positively anchored to the same reinforcing element 3, 3 ¹ via bores 34 which are provided in the reinforcing elements 3, 3 'and are penetrated by the thermoplastic.

In the composite component according to FIG. 5, the reinforcement elements 3, 3 'in the area of the connection points 4 and 5 are surrounded by walls 42 by these. In this case, the reinforcing elements 3, 3 ^{1 are divided} along the longitudinal axis 21 of the profile 2 on the underside 22. The mode of operation is not impaired as compared to the embodiment according to FIG. 4 and the assembly of the two halves of the reinforcing element 3 is simplified.

The composite components shown in FIGS. 1 to 7 show connections of profiles with a rectangular cross section. Since the inner contour of the reinforcing elements 3,

3 ', however, can be adapted to the contour of the profiles to be connected, other profile cross sections can also be connected to one another. If profiles with a circular cross-section are to be connected, by fitting feather keys,

Deformation of the profiles in the joining area to an oval cross section or similar measures to ensure sufficient torsional strength.

The composite component according to FIG. 6 is formed by profiles 1 and 2 and by two reinforcing elements 3 and 3 '(see also FIGS. 8 to 10), which are plugged onto the profiles 1 and 2 to be joined from both sides. Then the thermoplastic 4 is in the area of the connection point 10 on the to be connected

Profiles 1 and 2 and the reinforcing elements 3 and 3 'sprayed. In Fig. 6 on the left side of the figure, the positively joined profiles 1 and 2 and the reinforcing element 3 'are shown. The right-hand side shows the fully formed connection in which thermoplastic 4 is sprayed onto profiles 1 and 2 and reinforcing element 3. In this illustration, the reinforcing element 3 completely covered by connecting thermoplastics 4 and is therefore no longer visible.

The composite components according to FIGS. 6 and 7 show how the profile 2 is connected to profile 1 via the additional flanges 63 and 24. The reinforcing elements 3 and 3 ¹ ensure a high torsional rigidity by means of the walls 32 which form-fit the profiles 1 and 2 and by means of the support walls 31 for a high bending rigidity between the profiles 1 and 2. Connection thermoplastic 4, which comprises all the individual parts 1, 2, 3, 3 'encloses, secures the cohesion of the connection through the material tension built up in the injection molding process in the thermoplastic. The ribs 41 out

The inward arched support walls 31 support each other thermoplastic.

Connection of rod-shaped thin-walled hollow profiles: Figures 11 to 15

Example 2

11 and 12, a composite component is shown, which has an opening 35 on the back to allow the immersion of a core in the injection mold and thus the support of the hollow profiles 1, 2 and 8 during the injection molding process. When the composite component is manufactured, the parts to be joined are first

Components 1, 2 and 8 and the reinforcing elements 6, 6 'and 30 (see also FIG. 14) are placed in an injection mold. The thermoplastic component is then injected and the walls 42, the rib structure 41 and the fillings of the bores 34 are formed. In order to increase the rigidity of the composite component, the opening 35 can be closed with an after the thermoplastic component has been injected

Sheet metal to be closed.

The profiles 1, 2 and 8 to be connected are mutually supported by the support walls 31 of the reinforcing elements 6, 6 'and 30 and held together by the rib structure 41, the fillings of the bores 34 and the walls 42. The reinforcing elements 6, 6 'and 30 can be in beads (not shown) of the components 1, 2 and 8 can be embedded in order to achieve an additional positive connection between the reinforcing elements 6, 6 'and 30 and the profiles 1, 2, and 8 to be joined.

Another possibility for reinforcing composite components is shown in FIG. 13. A reinforcement element 136 is shown for reinforcing a corner, which is formed by three rod-shaped components, similar to that in FIG. 11. The profiles to be joined lie against the walls 32 and are supported against one another by the supporting walls 31. Through the bores 34, a rivet connection between the profiles to be joined and the reinforcing element 136 can be realized.

A solution is shown in the composite part according to FIG. 15, in which the effect of the injection pressure during the injection molding process is restricted to areas outside the hollow profiles to be joined. For this purpose, the hollow profiles 1 and 2 as well as the reinforcing elements 3 and 3 'are placed in an injection molding tool and only extrusion-coated with the thermoplastic component in the area of the support walls 31.

The thermoplastic component forms the connecting element 4, which is formed from the walls 42, the connecting webs 44 and the rivet heads 45. By means of the connecting webs 44 it is achieved that the walls 42 and the rivet heads 45 can be formed by means of a sprue over each of the two supporting walls 31 through the thermoplastic component. A riveted connection of the reinforcing elements 3, 3 'is produced via congruent bores (not shown) which are located in the supporting walls 31 of the reinforcing elements 3 and 3' in the area of the rivet heads 45. The connection of the reinforcing elements 3 and 3 'is additionally reinforced by an extrusion coating in the area of the wall 42.

The reinforcing elements 3 and 3 'can be embedded in the components 1 and 2 via beads (not shown) in order to achieve an additional positive connection between the reinforcing elements 3 and 3' and the profiles 1 and 2 to be connected. Connection of a thin-walled hollow profile with a U-profile using an integrated reinforcing element: Figures 16 to 18

Example 3

16, the hollow profile 161 is connected directly to the U-profile 162. Both profiles are made of metal and are shown separately in FIGS. 17 and 18 in the non-connected state. U-profile 162 is deeper in the connection area, so that there is a retaining wall on the top and bottom

21 can be integrated. In this embodiment, the profile has an integration of the reinforcing element. The function of the reinforcing element is taken over by the interaction of the parts 21, 23 and 25. By means of the rib structure 4 shown in FIG. 16 with the ribs 41 and the extrusion coating 42, the support walls 21 are kept in shape when loaded in order to prevent premature failure due to bulges. The hollow profile 161 is positively connected to the U-profile 162 by means of the interlocking beads 16 and 26. In the area of the openings 17 and 27, molded plastic rivets 45 can be formed on the connecting webs 44 of the rib structure 4, which secure the bond between the two profiles 161 and 162. To further improve the torsional rigidity of the composite component, the U-profile 162 is closed on the rear side via the wall 25 and flange 23. Flange 23 can also contain additional holes (not shown), which are also used to form riveted joints.

When manufacturing the composite component, the profile 161 is first in the profile

162 is inserted so that the profile 161 is in the recess 128 (see also FIG. 17) of profile 162. Then both profiles 161 and 162 are placed in an injection mold. By molding the thermoplastic component 4, the ribs 41, the extrusion coating 42, the connecting webs 44 and the plastic heap 45 are simultaneously formed. The connecting webs 44 ensure that the

Plastic melt both in the openings 17 during the injection molding process and 27 (see FIGS. 17 and 18), to form the plastic heap 45, and also to the flange 23 (see FIG. 17). This is used to form a molded edge (not shown) and again to form any further plastic rivets (not shown). The profile 161 is supported with the aid of a movable core in the injection molding tool, which dips into the hollow profile 161 through the opening 28 in the profile 162 in the connection area 10, in order to prevent the profile 161 from collapsing due to the high injection pressure during the injection molding process.

The type of connection shown in FIG. 16 can also be carried out with a U-profile rotated by 180 °. In addition, it is also suitable for joining profiles with the following profile combinations:

- Cylindrical hollow profile with U profile - U profile with U profile - U profile with double T profile

- U profile with Z profile

applications

Cross member for an instrument panel of a motor vehicle (Figures 19 to 20)

Example 4

FIG. 19 shows an example of an instrument panel cross member for a motor vehicle, which is composed of the tube segments 1, 2 and 7. The cross member is on the fender banks, not shown, via the flanges 136 and

736 or held in the holes 134 and 734 therein. In the middle it is supported by the two U-profiles 8. To attach the steering column (not shown), the U-profile 9 is attached to pipe segment 1. The profile 9 is fastened to the body via the flanges 936 and the bores 934 (see FIG. 21). The passenger airbag is on the holes 334 of the two fasteners

353, which are connected to the pipe segment 7, held. The individual profiles 1, 2, 3, 7, 8, 9 are plugged together and are held together by overmolding from thermoplastic 4. In order to be able to show the node areas of the connections between the profiles 1, 2, 3, 7, 8, 9, these are shown in FIG. 21 without thermoplastic overmolding. The profiles 1, 2, 7, 8, 9 are positively connected to one another via beads 126, 326 726, 826 and 926. A fixed connection of the individual components 1, 2, 7, 8 and 9 takes place via congruent bores 327, 827 and 927, which are filled by the thermoplastic overmoldings 4 (see FIG. 19). These connections are made by rivets 45 (see FIG. 20 ), which are formed as an integral part of the overmoldings 4 and 5. With the help of flanges 323, 823 and 923, the torsional rigidity of the connections is further improved. To reinforce the U profiles 8 and 9, they are provided with a rib structure 41. The rib structure 41 is connected to the overmolding 4 in the multi-part connection area via the edge encapsulation 42 and 47. The rib structure 41 is at the rib cross gen 48 anchored to the U-profile 8 or 9 via rivets 45. The recess 46 in the rib structure 41 of the U-profile 9 allows the steering column to be received.

To produce the cross member, the individual profiles 1, 2, 7, 8 and 9 are first put together. In addition, it is possible to manufacture pipe segments 1, 2 and 7 from a pipe (by internal high-pressure forming (IHU)) or from two half-shells that are divided lengthways. The assembled profiles 1, 2, 7, 8 and 9 are placed in an injection mold. The mold is closed and a core, which is part of the injection molding tool, dips into the opening of profiles 1 and 7. The cores are designed so that they are in the retracted position

Map the inner contour of pipe segments 1, 2 and 7. The thermoplastic is then injected and the thermoplastic overmoldings 4 and 5 with the molded-on rib structures 41, overmolding 42 and 47 are formed. The movable tool cores, which are in the pipe segments 1, 2 and 7 during the injection molding process, prevent them from collapsing due to the high injection pressure.

Example 5

Door structure for a commercial vehicle (Fig. 22 and 23)

FIG. 22 shows the connection of the profiles 221, 222, 227, 228 and 229 to a door frame structure with thermoplastic overmolding 224. In FIG. 23 again, only the profiles 221, 222, 227, 228 and 229 without thermoplastic overmolding are shown to illustrate the connection areas , Profiles 221, 228 and

229 consist of torsionally rigid closed box profiles. The profile 228 forms the window frame and is widened at the lower ends so that it can be plugged together with the profiles 221 and 229. In a further embodiment variant, the profiles 221, 228 and 229 can also be welded together from individual parts or consist of an IHU part. Profiles 222 and

227 are U-shaped profiles with a thermoplastic rib structure 41 are reinforced. A positive connection between the profiles 221, 222, 227, 228 and 229 is produced via congruent beads 226, 726 and 826. The thermoplastic overmoldings 224 hold the assembled individual parts 221, 222, 227, 228 and 229 firmly together.

To manufacture the door structure, profiles 221 to 229 are put together and placed in an injection mold. The box profiles 221 and 229 are filled with movable tool cores in a manner similar to the previous application example and are thereby supported during the injection molding process. By injecting the thermoplastic plastic, the overspray 224 in the

Connection areas and the rib structures 41 are formed.

Example 6

Support structure tailgate for a motor vehicle (Fig. 24)

The structure shown in FIG. 24 consists of a torsionally rigid box profile 241, two side U-profiles 242, 242 ', which are predominantly subjected to bending, and for further stiffening the frame structure, a further U-profile 247 and a Z-profile 248. The profiles 247 and In other versions, 248 can also consist of U-profiles or closed box profiles. The U-profiles 242, 242 'and 247 are reinforced with a rib structure 41. The Z-Profile 248 can also be equipped with ribs or functional elements to hold windows, wiper motor, lock, etc. (not shown). The thermoplastic overmoldings 244 hold the individual profiles 241, 242, 242 ', 247 and

248 together. They are positively anchored to each other via beads (not shown), similar to the cross member. The opening 11 serves to support the box profile 241 during the injection molding process. The production takes place similar to the previous application examples by plugging together the profiles 241, 242, 242 ', 247 and 248 and then overmolding the

Connection areas with thermoplastic 244.

Claims

Patentansprflche

1. Composite component consisting of two or more profiles (1) and (2), in which at least one profile (1) adjoins the second profile (2) with a free end or is immersed in the second profile (2), characterized in that in the area of the connection point (10) of the profiles (1) and (2) reinforcement elements (3, 3 '; 6, 6'; 23; 25; 21) are attached, which form-fit with the profiles (1) and (2) form, and that the profiles (1) and (2) are connected to each other by thermoplastic or molded or shrunk on in the area of the connection point (10).

2. Composite component according to claim 1, characterized in that the profiles (1, 2) have a closed, in particular round or rectangular, or an open, in particular U-shaped cross section.

3. Composite component according spoke 2, characterized in that the profiles (1, 2) are closed profiles.

4. Composite component according to one of claims 1 to 3, characterized in that the reinforcing elements (3, 3 '; 6, 6'; 23; 25; 21) made of metal, in particular steel, aluminum or magnesium, ceramic or high-strength Kimststoff , in particular thermosets or long-fiber reinforced plastic or made of plastics that are reinforced with technical textiles.

5. Composite component according to one of claims 1 to 4, characterized in that the reinforcing elements (3, 3 '; 6, 6'; 23; 25; 21) are designed as clips, rings or half-shells.

6. Composite component according to one of claims 1 to 5, characterized in that the reinforcing elements (3, 3 '; 6, 6'; 23; 25; 21) with additional

Support walls (31) are provided

7. Composite component according to one of claims 1 to 6, characterized in that a one-piece reinforcing element is provided at the connection point (10) in which the profiles are inserted or inserted before the injection molding of the thermoplastic material.

8. Composite component according to one of claims 1 to 7, characterized in that in the profiles (1, 2) and / or in the reinforcing elements (3, 3 '; 6, 6'; 23; 25; 21) at points one above the other, Openings (34) or bores are provided through which the thermoplastic material projects and to which the thermoplastic material is anchored.

9. Composite component according to one of claims 1 to 8, characterized in that in the profiles (1, 2) and / or in the reinforcing elements (3, 3 '; 6, 6'; 23; 25; 21) at points one above the other, Deformations (16, 26), in particular beads or beads, are provided on which the thermoplastic is anchored.

10. Composite component according to one of claims 1 to 9, characterized in that the thermoplastic is an unreinforced or reinforced or filled plastic, preferably based on polyamide (PA), polyester, in particular polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyolefin , in particular polypropylene (PP), polyethylene (PE), styrene-acrylonitrile copolymer, in particular acrylonitrile-styrene-butadiene copolymer (ABS), polycarbonate (PC), polypropylene oxide (PPO), (PSO), polyphenylene sulfide (PPS),

Polyimide (PI), (PEEK), polyketone, syndiotactic polystyrene (PS) or a possible mixture of these plastics is used.

11. Composite component according to one of claims 1 to 10, characterized in that the reinforcing elements (21, 23, 25) with at least one of the profiles (1) or (2) are formed in one piece, and that the profiles (1) and (2) form a positive fit with each other.

12. Use of the composite component according to one of claims 1 to 11 as a construction element for machines, vehicles and components of all kinds, in particular for motor vehicles, for electronic articles, household articles and for building requirements.

13. Use of the composite component according to one of claims 1 to 11 as a structural part for motor vehicles, in particular doors, bumpers, beams,

Front and rear parts for cars, door sill support frames, instrument panel supports, tailgate supports, roof frames and decorative elements.

14. A method for producing a composite component according to one of claims 1 to 11, characterized in that two or more profiles (1, 2) in reinforcing elements (3, 3 '; 6, 6'; 23; 25; 21) inserted or inserted or by reinforcing elements (3, 3 '; 6, 6'; 23; 25; 21) to form a detachable connection point (10) and that the connection point (10) is then completely or partially encapsulated in an injection mold by thermoplastic material, the profiles (1, 2) being connected to the reinforcing elements (3, 3 '; 6, 6'; 23; 25; 21).

15. A method for producing a composite component according to one of claims 1 to 11, characterized in that two or more profiles (1, 2) are inserted into reinforcing elements (3, 3 '; 6, 6';23;25; 21) or inserted or clasped by reinforcing elements (3, 3 '; 6, 6';23;25; 21) to form a detachable connection point (10) and that the connection point (10) is then fitted with one or more shaped pieces (4, 5) is completely or partially surrounded by shrinkable thermoplastic, and the profiles (1, 2) with the reinforcing elements (3, 3 '; 6, 6';23; 25; 21) are then connected by heat treatment of the shaped pieces (4, 5).

16. The method according to claim 14 or 15, characterized in that open profiles (8, 9, 162, 242, 242 ', 247, 222, 227) are used and in the open profiles (8, 9, 162, 242, 242 *, 247, 222, 227) reinforcing struts (41) are produced when the thermoplastic is molded on.

17. The method according to claim 14 to 16, characterized in that when molding the thermoplastic in the area of the connection point

(10) additional reinforcing struts (41) are generated.

18. The method according to any one of claims 14 to 17, characterized in that in the profiles (1, 2) and / or in the reinforcing elements (3, 3 '; 6, 6'; 23; 25; 21) before folding or Pushing in deformations (16, 26), in particular beads or beads, and / or openings (34) or bores at certain points in the profiles (1, 2) and / or the reinforcing elements (3, 3 '; 6, 6'; 23 ; 25; 21), so that they lie on top of each other when the profiles (1, 2) and / or the reinforcing elements (3, 3 '; 6, 6'; 23; 25; 21) are folded or pushed in.