EP3740366A1 - Hybrid part made of composite material comprising at least one metal insert and method for manufacturing such a part - Google Patents

Hybrid part made of composite material comprising at least one metal insert and method for manufacturing such a part

Info

Publication number
EP3740366A1
EP3740366A1 EP19700525.9A EP19700525A EP3740366A1 EP 3740366 A1 EP3740366 A1 EP 3740366A1 EP 19700525 A EP19700525 A EP 19700525A EP 3740366 A1 EP3740366 A1 EP 3740366A1
Authority
EP
European Patent Office
Prior art keywords
insert
relief
mold
reliefs
composite material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP19700525.9A
Other languages
German (de)
French (fr)
Inventor
Lionel Meslin
Yves BONNEMAYRE
Arnaud CARADEC
Hervé MOTTE
Denis LATTAY
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Faurecia Automotive Composites SAS
Shapers France SAS
Stellantis Auto SAS
Original Assignee
Faurecia Automotive Composites SAS
PSA Automobiles SA
Shapers France SAS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Faurecia Automotive Composites SAS, PSA Automobiles SA, Shapers France SAS filed Critical Faurecia Automotive Composites SAS
Publication of EP3740366A1 publication Critical patent/EP3740366A1/en
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C45/14221—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure by tools, e.g. cutting means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/681—Component parts, details or accessories; Auxiliary operations
    • B29C70/682—Preformed parts characterised by their structure, e.g. form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/72—Encapsulating inserts having non-encapsulated projections, e.g. extremities or terminal portions of electrical components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
    • B29C70/882—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding
    • B29C70/885—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding with incorporated metallic wires, nets, films or plates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B62D29/004—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material the metal being over-moulded by the synthetic material, e.g. in a mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14065—Positioning or centering articles in the mould
    • B29C2045/14131—Positioning or centering articles in the mould using positioning or centering means forming part of the insert
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • B29C2045/14327—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles anchoring by forcing the material to pass through a hole in the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14336—Coating a portion of the article, e.g. the edge of the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3002—Superstructures characterized by combining metal and plastics, i.e. hybrid parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/20—Floors or bottom sub-units
    • B62D25/2054—Load carrying floors for commercial vehicles

Definitions

  • Hybrid parts comprising a plastic or composite material and at least one metal insert, such as, for example, vehicle load floors, or electric vehicle battery trays, as well as motor vehicles comprising such hybrid parts.
  • the invention also relates to the methods of manufacturing such hybrid parts.
  • hybrid parts comprising one or more metal elements (inserts) in plastic or composite bodies.
  • the composite materials comprise a matrix of thermoplastic material or thermosetting material, loaded with reinforcing elements such as, for example, glass fibers or carbon fibers. This is particularly the case for some rear load floors of vehicles.
  • Such floors are, for example, described in WO2014131967. They consist of a composite material part and a metal peripheral edge intended to be welded to the metal rear part of a motor vehicle underbody. This metal edge (insert) is partially embedded in the composite material during the manufacture of the floor.
  • WO0187568 discloses a method of manufacturing a molded piece from a plastic / metal compound by internal high pressure forming of metal tubular semi-product.
  • the semi-finished product is placed in a forming tool at least in two parts, the forming space of which corresponds to the outer contour of the part to be molded.
  • the forming tool is closed.
  • the tubular semifinished product is insulated at its open end sides by means of a pressure-proof packing and is formed in said forming space from at least one front side by means of a pressure-proof packing.
  • a polymer melted under high pressure.
  • the molten polymer is compressed in the semi-finished product by injection molding using a conventional injection molding aggregate. Once the molten polymer is sufficiently solidified at the walls of the metal molded part, said molten polymer is removed from said part so as to obtain a metal molded part provided with a plastic lining.
  • EP0594131 discloses a vehicle subframe composite structure having improved structural performance through the use of closed structure profiles, the orientation of the reinforcing fibers, and the selected use of inserts in compared to comparable steel structures.
  • the inserts have fastening means the fiber reinforcement helps to ensure their positioning during the injection of the polymer resin. The implementation of such a solution therefore involves the use of fiber reinforcement.
  • a molding process of a part comprising at least one partially molded insert is known from WO20171 15026.
  • the proposed solution involves the use of specific molds having a system for positioning and holding the insert in the mold. It would be interesting to find simpler solutions to maintain an insert in position in a mold during the manufacture of a part.
  • the aim of the invention is to meet at least one of the problems encountered in the prior art by proposing a new hybrid part made of composite material and comprising at least one metal insert, said part comprising at least one insert configured to ensure itself. its positioning in the injection mold.
  • the invention also aims to propose a new process for manufacturing such hybrid parts.
  • the invention relates to novel functionalized metal inserts in that they comprise means for positioning in a mold, for example compression or injection molding or overmoulding.
  • the molding may be made by compression of a sheet molding compound (SMC), or a composite material glass felt - thermoplastic material (GMT for "Glass Mat Thermoplastic"). " in English).
  • the subject of the invention is a hybrid part for a motor vehicle comprising at least one metal insert overmolded in a layer of plastic or composite material, the insert comprising a body showing an upper face and a lower face, and being at at least partially covered on at least one of its faces by a layer of said plastic or composite material of a defined thickness; the piece being remarkable in that the insert comprises at least one relief extending from one of its faces and in that the height presented by the relief or reliefs is less than or equal to the thickness of said layer of plastic material or composite, overmolded on said face of the insert.
  • the invention consists in providing the piece with functionalized inserts having at least one relief intended to bear against the wall of the mold during the molding operation of the part, including overmoulding of the insert.
  • the molding method used is an injection molding process.
  • the relief or reliefs will act as wedges ensuring the positioning of the insert in the mold according to a predefined position.
  • the relief or reliefs are contained in the thickness of the layer of plastic or composite material overmolded on the face of the insert from which they extend.
  • the reliefs presented by the insert are not intended to exceed the layer of plastic or composite material in which they are embedded. They are intended to be fully contained.
  • the part may comprise one or the other of the following characteristics taken separately or in any combination possible:
  • the or at least one of the reliefs is integrally contained in the thickness of the layer of plastic or composite material overmolded on said face of the insert.
  • the insert comprises at least one relief extending from each of its lower and upper faces.
  • the insert is a profile comprising at least one lateral face and the insert comprises at least one relief extending from the or at least one of the lateral faces.
  • the metal insert comprises at least three non-aligned reliefs extending from one of its faces, preferably from each of its faces.
  • the height presented by the relief or reliefs, as measured from the face of the insert from which they extend, is equal to the thickness of the layer of plastic or composite material, overmolded on said face of the insert.
  • At least one relief is combined with a creep path allowing the passage of the plastic or composite material through said insert during the overmolding operation.
  • the insert further comprises at least one creep hole allowing the plastic or composite material to pass through the insert during the overmolding operation.
  • the relief or reliefs are in the form of bumps, ribs, lined holes, tabs cut and folded from the body of the insert and / or in the form of stamped sheet metal strips cut into the body of the insert and having two ends connected to said body.
  • the relief or reliefs are in the form of a hump associated with a creep path, the insert having a recessed shape on the face opposite to that comprising the relief, complementary to the hump-shaped shape, vis-à-vis said hump shape.
  • the relief or reliefs are obtained by deformation of the sheet forming the body of the insert, so as to form the recessed shape on the face opposite to that comprising the relief, of shape complementary to the bump shape, vis-à-vis -vis of said form of hump.
  • the relief or reliefs are elongated curved zones.
  • a creep path is disposed at one end of the elongated curved zone.
  • the insert is in the form of a metal sheet or a profile.
  • the hybrid part constitutes a load floor made of composite material comprising a metal edge intended to be welded to the rear part of the base. of a motor vehicle, preferably the metal edge is a free part of a metal insert partially overmolded in the composite material of which the floor is made.
  • the subject of the invention is a vehicle, preferably a motor vehicle, which is remarkable in that it comprises at least one hybrid part as defined according to the first aspect of the invention.
  • the subject of the invention is an insert for a hybrid part as defined according to the first aspect of the invention, the insert comprising a body showing an upper face and a lower face and being remarkable in that it comprises at least one relief extending from one of its faces, the height of said relief being chosen as a function of the thickness of the layer of plastic or composite material intended to be overmolded on said face of the insert, so as to be less than or equal to the thickness of said layer, preferably the insert is in the form of a metal sheet or a profile.
  • the subject of the invention is an insert for a hybrid part as defined according to the first aspect of the invention, the insert comprising a body showing an upper face and a lower face and being remarkable in that it comprises less a relief extending from one of its faces, and in that at least one relief is combined with a creep path allowing the passage of the plastic or composite material through said insert during an overmolding operation of said insert.
  • at least one relief is associated with, or adjacent to, a creep path.
  • the subject of the invention is a method for manufacturing a hybrid part according to the first aspect, said hybrid part comprising at least one metal insert at least partially overmoulded in a layer of plastic or composite material, the process using a mold comprising a lower portion and an upper portion, and comprising the steps of:
  • the method is remarkable in that the insert or at least one of the inserts comprises at least one relief extending from one of its faces and in that:
  • the one or more inserts when closing the mold, are in contact with the upper part of the mold by the relief or reliefs extending from their upper face disposed facing the upper part of the mold.
  • the invention relates to a method for manufacturing a hybrid part as defined according to the first aspect, said hybrid part comprising at least one insert at least partially overmolded by one or more blanks of sheet molding mixture ( SMC) or glass fiber composite material - thermoplastic material (GMT), the method using a mold comprising an upper part and a lower part and comprising the following steps:
  • the method is remarkable in that the insert or at least one of the inserts comprises at least one relief extending from one of its faces and in that:
  • this or at least one of these is in abutment against the or at least one of the SMC or GMT blanks by the relief or reliefs extending from their underside , and / or in that the or at least one of the SMC or GMT blanks bears on the or at least one of the reliefs extending from the upper face of the or at least one of the inserts.
  • the invention relates to a method for manufacturing a hybrid part as defined according to the first aspect, said hybrid part comprising at least one insert at least partially molded by one or more sheet molding mixture blanks (SMC ), the method using a mold comprising an upper portion and a lower portion and comprising the steps of:
  • the method is remarkable in that the insert or at least one of the inserts comprises at least one relief extending from one of its faces and in that:
  • this or at least one of these is in support against the or at least one of the SMC blanks by the relief or reliefs extending from their underside, and / or or in that the or at least one of the SMC blanks bears on the or at least one of the reliefs extending from the upper face of the or at least one of the inserts.
  • the invention relates to a method of manufacturing a hybrid part as defined according to the first aspect, said hybrid part comprising at least one insert at least partially molded by one or more blanks of composite glass felt material - thermoplastic material (GMT), the method using a mold comprising an upper part and a lower part and comprising the following steps:
  • the method is remarkable in that the insert or at least one of the inserts comprises at least one relief extending from one of its faces and in that: when placing the insert (s) in the mold, this or at least one of these is in abutment against the or at least one of the blanks of GMT by the relief or reliefs extending from their lower face, and / or in that the or at least one of the blanks of GMT is in support on the or at least one of the reliefs extending from the upper face of the or at least one of the inserts.
  • FIG. 1 shows an example of metal insert according to the invention.
  • Figures 2 and 3 illustrate the positioning of the insert in the mold and in the layer of polymeric material because of the reliefs it has on its lower and upper faces.
  • Figure 4 is a partial view of an embodiment of an insert according to the invention having a mixture of reliefs and creep holes.
  • the reliefs shown are in the form of stamped sheet metal strips cut into the body of the insert and having two ends connected to said body.
  • Figure 5 is a partial view of an embodiment of an insert according to the invention, the reliefs are in the form of lined holes.
  • Figure 6 is a partial view of an embodiment of an insert according to the invention, the reliefs are in the form of tabs cut and folded from the body of the insert.
  • Figure 7 is a partial view of an embodiment of an insert according to the invention, the reliefs are in the form of a bump and are associated with creep holes.
  • Figure 8 is a partial view of an embodiment of an insert according to the invention, the reliefs are in the form of elongated bumps, and having a creep path at one end of these elongated bumps.
  • understand is synonymous with “include” and is not limiting in that it permits the presence of other elements in the room or in the vehicle to which it refers and / or other steps in the process to which it refers. It is understood that the term “understand” includes the words “consist of”. In the different figures, the same references designate identical or similar elements.
  • the term “lower” will mean a greater ground proximity than “higher” along a vertical axis. Note that in the context of the description which follows the lower and upper faces of the insert are defined with respect to its positioning in the mold during the manufacture of the hybrid part and not according to the future positioning of the part in the vehicle. In the context of the invention, the term “resin” will be considered synonymous with "polymer matrix”.
  • the invention relates to a hybrid part for a motor vehicle comprising at least one metal insert overmolded in a layer of plastic or composite material.
  • An example of such an insert 1 is shown in FIG. It is an insert intended to form the frame of a load floor of a motor vehicle. More specifically it is a stamped to form the rear part of the frame of a floor (not shown) of plastic or composite material, preferably composite material.
  • the insert 1 shown is intended to be only partially overmoulded, so that the formed floor has a border 3 metal which can be welded to the underbody elements of a vehicle. This metal edge is said to be free in that it is not covered with plastic or composite material. Nevertheless, the invention can be applied to other types of inserts and parts.
  • the insert 1 comprises at least one relief 5 intended to ensure its positioning in the mold during the overmolding operation.
  • the insert 1 comprises at least one relief 5 extending from one of its faces and in that the height, presented by the relief or reliefs 5, is less than or equal to the thickness of the layer of material plastic or composite, overmolded on said face of the insert 1.
  • the insert comprises a body 9 in the form of a metal sheet or a profile having a lower face and an upper face (7a, 7b illustrated in Figure 2).
  • the insert 1 comprises at least three reliefs 5 non-aligned on at least one of its faces 7 and preferably on each of its faces 7.
  • the insert 1 comprises reliefs 5 extending from the two upper and lower faces 7 of its body 9. Those skilled in the art will have the advantage that said reliefs 5 show a height similar to that of the thickness of the plastic or composite material which is overmolded on each of the faces of said insert 1.
  • the invention also relates to a manufacturing method, illustrated in FIGS. 2 and 3, of a hybrid part 1 1 comprising at least one insert 1 overmolded in a layer of a plastic or composite material, by means of a mold comprising a lower part 13 and an upper part 15.
  • the method comprising the following steps:
  • the method is remarkable in that the insert or at least one of the inserts comprises at least one relief extending from one of its faces and in that:
  • the invention also relates to a method of manufacturing a hybrid part comprising at least one insert molded by one or more SMC blanks, by means of a mold comprising an upper part and a lower part.
  • the method comprises the following steps: placing the insert (s) and the SMC blank (s) in the lower part of the mold, the or at least one of the blanks being in contact with the upper or lower face of the or at least one of the blanks one of the inserts;
  • the insert or at least one of the inserts comprises at least one relief extending from one of its faces and in that: when placing the insert (s) in the mold, this or at least one of these is in abutment against the or at least one of the SMC blanks by the relief or reliefs extending from their lower face, and / or in that the or at least one of the SMC blanks is supported on the or at least one of the reliefs extending from the upper face of the or at least one of the inserts.
  • the invention further relates to a method for manufacturing a hybrid part comprising at least one insert molded by one or more blanks of GMT, by means of a mold comprising an upper part and a lower part.
  • the method comprises the following steps: heating the blank (s) of GMT;
  • the insert or at least one of the inserts comprises at least one relief extending from one of its faces and in that: when placing the insert (s) in the mold, this or at least one of these is in support against the or at least one of the blanks of GMT by the reliefs extending from their lower face, and / or in that the or at least one of the GMT blanks bears on the or at least one of the reliefs extending from the upper face of the or at least one of the inserts .
  • the insert 1 has reliefs 5a on its lower face 7a intended to be arranged facing the lower part of the mold 13, or facing a blank of SMC or GMT, and that said insert 1 is put into position. placed in the mold, it will rest against the inner wall of the lower part 13 of the mold through the reliefs 5a which extend from its lower face 7a, or against the surface of a blank of SMC or GMT.
  • the presence of at least three non-aligned reliefs 5a on this lower face 7a thus allows a stable support and a correct orientation of the insert 1 in the mold.
  • the insert 1 When the insert 1 has reliefs 5b on its upper face 7b intended to be arranged facing the upper part 15 of the mold, or facing a blank of SMC or GMT, and the mold is closed, the insert 1 will be in contact with the inner wall of the upper part 15 of the mold or with the surface of a blank of SMC or GMT.
  • the insert 1 has reliefs 5 on its two lower faces 7a and 7b, so that the closing of the mold will fix in position the insert 1 in the mold, for example in a central position according to the height of the mold .
  • the invention is remarkable in that it does not need the mold to be provided with means for positioning the insert 1.
  • the positioning means in the mold are constituted by the reliefs 5 that the insert 1 has.
  • the reliefs 5 carried by the insert 1 are in the form of stamped sheet metal strips 19 (see Figure 4) cut into the body 9 of the insert 1 and having two ends connected to said body.
  • This type of relief is advantageous in that it creates creep zones 21 allowing the passage of the plastic or composite material through the insert, and promotes the anchoring of the insert 1 in the hybrid part.
  • the creep paths of the material through the insert 1 and more precisely of its reliefs 5 are illustrated in FIGS. 2 and 3.
  • the body 9 of the insert 1 has at least one creep hole 23, or a journeyage, allowing the passage of plastic or composite material through the insert 1 during the overmolding operation.
  • the insert may have both creep paths associated with the reliefs 5 and creep holes 23 not associated with the reliefs.
  • creep paths 21 are associated with the reliefs 5.
  • the operation of forming the relief or reliefs 5 will create a hole 21 in the body 9 of the insert 1. This is, for example, the case when the shaping of the reliefs comprises punching operations and or cutting the sheet forming the insert 1.
  • the relief 5 may be a bordered hole 25, that is to say an openwork 27 surrounded by a rim 29, the rim 29 forming the relief 5 for the positioning of the insert 1.
  • the opening 27 forming the creep path 21 associated with the relief 5.
  • the relief 5 may be constituted by one or more lug 31 cut into the sheet forming the body 9 of the insert 1 and folded.
  • the flow path 21 associated with the relief 5 is constituted by the openwork 33 created by the cutting-folding of the one or more lugs 31.
  • the relief 5 is in the form of an elongated curved zone 45 extending on one of the faces 7 of the insert 1.
  • the face of the insert 1 opposite to that comprising the relief 5, has a recessed area 46 vis-à-vis the relief 5, complementary shape to said relief 5.
  • the recessed area 46 also has an elongated shape.
  • the elongated curved area is on the face 7a and the recessed area 46 on the face 7b.
  • the relief 5 is obtained for example by deformation of the sheet forming the body 9 of the insert 1, for example by stamping. The deformation of this sheet forming the body 9 creates on one of the faces of the insert 1 the elongated convex zone 45 and on the opposite face of said insert 1 the recessed zone 46.
  • a creep channel 21 is formed at the one of the ends of this elongated curved zone 45.
  • This creep path 21 can be made for example by cutting the sheet forming the body 9, at the time of stamping the sheet forming the body 9 of the insert, by example by punching. As shown in FIG. 8, this creep path 21 forms an opening at the end of the elongated convex zone 45, passing through the insert 1. That is to say that one of the ends of the elongated curved zone 45 opens into this opening forming the creep path 21, the hollow zone 46 also opening at its end in the same opening.
  • the recessed area 46 guides the plastic or composite material to the creep path 21 which is associated with the relief 5, creating a channel directing the displacement of the plastic or composite material towards said flow path 21, during overmoulding of the plastic or composite material on the insert 1.
  • the insert 1 may comprise several elongated curved zones 45 on one of the faces 7a or 7b of the insert 1.
  • elongated convex zones 45 are disposed on each of the two faces 7a and 7b of the insert 1, and the insert 1 also has recessed areas 46 on each of these faces 7a and 7b.
  • the relief 5 is in the form of a half hemisphere, with a creep path 21 adjacent to said relief so that the edge of the hemisphere protruding from the insert 1 forms at least part of one of the edges of said creep path 21.
  • the relief or reliefs of the insert 5 are made by stamping so that their shaping does not create a creep path (or holes). in the sheet forming the body 9 of the insert.
  • the reliefs 5 may be in the form of circular or elongate bumps, or in the form of ribs extending over all or part of the insert 1 in any direction.
  • the skilled person will benefit from using an insert 1 also having creep holes 23.
  • the height "h" presented by the relief or reliefs 5 extending from a face 7 of the insert 1 is equal to the thickness "e" of the layer of plastic or composite material 17, overmolded on said face 7 of the insert 1. Nevertheless, it may happen in some cases that during the overmolding operation, the material (or resin) injected into the mold infiltrates between the mold and the ends of the reliefs 5 placed in support against the walls of the mold.
  • the height "h” presented by the relief or reliefs 5, as measured from the face 7 of the insert 1 of which they extend corresponds to at least 90% of the thickness of the layer of plastic or composite material overmolded on said face 7 of the insert, preferably at least 95%, more preferably at least 98%.
  • the height "h” presented by the relief or reliefs 5, as measured from the face 7 of the insert 1 of which they extend is less than or equal to the thickness "e" of the layer of plastic or composite material 17, overmolded on said face 7 of the insert 1.
  • the hybrid part 1 1 according to the invention can be made of plastic materials or composite material, preferably composite material.
  • the selected composite material can be a thermoplastic or thermosetting composite material.
  • the composite materials are defined in the context of the invention as having a polymer matrix and one or more reinforcing elements.
  • the reinforcing elements comprise or consist of fibers or a mixture of fibers selected from glass, carbon, ceramic, graphite, natural fibers such as flax, hemp or bamboo fibers, organic polymers such as than polyester fibers.
  • the fibers of the reinforcing elements are glass fibers.
  • thermoplastic polymer matrix will advantageously be selected from one or more materials selected from polypropylenes (PP), polyphthalamides (PPA), polyetheretherketones (PEEK), phenylene polysulfides (PPS), polyamide imides (PAI), polyetherimides (PEI), polyarylamides (PAA), or polyamides (PA) such as for example polyamide 6 (PA 6 or polycaprolactam) or polyamide 6.6 (PA 6.6 or polyhexamethylene adipamide).
  • PP polypropylenes
  • PPA polyphthalamides
  • PEEK polyetheretherketones
  • PPS phenylene polysulfides
  • PAI polyamide imides
  • PEI polyetherimides
  • PAA polyarylamides
  • PA polyamides
  • thermosetting polymer matrix will advantageously be selected from unsaturated polyesters, polyurethanes, vinylesters or polyepoxides.
  • the insert may be totally or partially embedded in the plastic or composite material.
  • the insert 1 is partially overmolded.
  • the insert 1 has a portion overmolded on at least one of its faces and a free portion in that it is not covered with material (or resin).
  • the free part 3 and the part intended to be overmoulded are arranged to extend perpendicularly with respect to each other as illustrated in FIGS. 1, 3 and 4.
  • the hybrid part is a load floor of a motor vehicle.
  • said floor is made of composite material.
  • the load floor is polyester filled with fiberglass.
  • the floor advantageously comprises a metal rim intended to be welded to the rear part of the underbody of the vehicle, as is the case for all-metal load floors.
  • This metal edge is constituted by one or more inserts according to the invention, so that the inserts or are partially overmolded in the floor and have a portion embedded in the plastic or composite material and an outer portion to be welded.
  • the load floor comprises a plurality of inserts, at least one being disposed on each of its edges.
  • the insert or inserts are preferably made of steel and are in the form of a stamped sheet and / or in the form of profiles.
  • the insert can also be aluminum or magnesium.
  • the inserts form a frame.
  • the inserts arranged at the front and rear of the floor are stampings and the two side portions are profiles.
  • the portion of the rear floor, composite material only has stiffening ribs and possibly a cavity for receiving the spare wheel.

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Abstract

The invention concerns a hybrid part (11) for a motor vehicle, comprising at least one metal insert (1) overmoulded in a layer of plastic or composite material (17), the insert (1) being at least partially covered on at least one of its faces (7a, 7b) by a layer of material of a given thickness; and comprising at least one relief (5) extending from one of its faces (7a, 7b). The height exhibited by the releif or reliefs (5) is less than or equal to the thickness of the layer of plastic or composite material overmoulded on said face (7a, 7b) of the insert (1), so that the contact between the reliefs (5) and the walls of the mould ensures the positioning of the insert (1) in the mould during the overmoulding operation.

Description

PIECE HYBRIDE EN MATERIAU COMPOSITE COMPRENANT AU MOINS UN INSERT METALLIQUE ET PROCEDE DE FABRICATION D’UNE TELLE PIECE.  HYBRID PIECE OF COMPOSITE MATERIAL COMPRISING AT LEAST ONE METAL INSERT AND METHOD OF MANUFACTURING SUCH A PART
L’invention concerne des pièces hybrides comprenant un matériau plastique ou composite et au moins un insert métallique, telles que, par exemple, des planchers de charge de véhicule, ou des bacs de batteries de véhicule électrique, ainsi que les véhicules automobiles comprenant de telles pièces hybrides. L’invention a également trait aux procédés de fabrication de telles pièces hybrides. Hybrid parts comprising a plastic or composite material and at least one metal insert, such as, for example, vehicle load floors, or electric vehicle battery trays, as well as motor vehicles comprising such hybrid parts. The invention also relates to the methods of manufacturing such hybrid parts.
Afin d’alléger le poids global des véhicules et donc de diminuer les émissions de dioxyde de carbone, l’industrie automobile utilise des pièces hybrides comprenant un ou plusieurs éléments métalliques (inserts) dans des corps en matière plastique ou composite. Les matières composites comprennent une matrice en matériau thermoplastique ou en matériau thermodurcissable, chargée en éléments de renfort tel que, par exemple, des fibres de verre ou des fibres de carbone. C’est le cas notamment pour certains planchers de charge arrière de véhicules. De tels planchers sont, par exemple, décrits dans le document WO2014131967. Ils sont constitués d’une partie en matériau composite et d’une bordure périphérique en métal destinée à être soudée à la partie arrière en métal d’un soubassement de véhicule automobile. Cette bordure métallique (insert) est en partie noyée dans le matériau composite lors de la fabrication du plancher. In order to lighten the overall weight of vehicles and thus reduce carbon dioxide emissions, the automotive industry uses hybrid parts comprising one or more metal elements (inserts) in plastic or composite bodies. The composite materials comprise a matrix of thermoplastic material or thermosetting material, loaded with reinforcing elements such as, for example, glass fibers or carbon fibers. This is particularly the case for some rear load floors of vehicles. Such floors are, for example, described in WO2014131967. They consist of a composite material part and a metal peripheral edge intended to be welded to the metal rear part of a motor vehicle underbody. This metal edge (insert) is partially embedded in the composite material during the manufacture of the floor.
Les techniques de fabrication de pièces par moulage ou surmoulage sont connues. Par exemple, le document WO0187568 décrit un procédé de fabrication d'une pièce moulée à partir d'un composé plastique/métallique par formage haute pression interne de demi-produit tubulaire métallique. Dans le procédé décrit, le demi-produit est placé dans un outil de formage au moins en deux parties, dont l'espace de formage correspond au contour extérieur de la pièce à mouler. L’outil de formage est alors fermé. Le demi-produit tubulaire est isolé au niveau de ses côtés frontaux ouverts par le biais d'une garniture à l'épreuve de la pression et est formé, dans ledit espace de formage, à partir d'au moins un côté frontal au moyen d'un polymère fondu sous haute pression. Le polymère fondu est comprimé dans le demi-produit par moulage par injection au moyen d'un agrégat de moulage par injection classique. Une fois que le polymère fondu est suffisamment solidifié au niveau des parois de la pièce moulée métallique, on retire ledit polymère fondu de ladite pièce, de manière à obtenir une pièce moulée métallique pourvue d'un revêtement interne en plastique. The techniques for manufacturing parts by molding or overmolding are known. For example, WO0187568 discloses a method of manufacturing a molded piece from a plastic / metal compound by internal high pressure forming of metal tubular semi-product. In the method described, the semi-finished product is placed in a forming tool at least in two parts, the forming space of which corresponds to the outer contour of the part to be molded. The forming tool is closed. The tubular semifinished product is insulated at its open end sides by means of a pressure-proof packing and is formed in said forming space from at least one front side by means of a pressure-proof packing. a polymer melted under high pressure. The molten polymer is compressed in the semi-finished product by injection molding using a conventional injection molding aggregate. Once the molten polymer is sufficiently solidified at the walls of the metal molded part, said molten polymer is removed from said part so as to obtain a metal molded part provided with a plastic lining.
Le document EP0594131 décrit une structure composite de sous-châssis pour véhicule ayant des performances structurelles améliorées au travers de l'utilisation de profils de structure fermés, de l'orientation des fibres d'armature, et de l'utilisation choisie d'inserts en acier, par rapport à des structures comparables en acier. Les inserts présentent des moyens de fixation à l’armature en fibres aidant à garantir leur positionnement durant l’injection de la résine polymère. La mise en oeuvre d’une telle solution implique donc l’utilisation d’armatures en fibres. EP0594131 discloses a vehicle subframe composite structure having improved structural performance through the use of closed structure profiles, the orientation of the reinforcing fibers, and the selected use of inserts in compared to comparable steel structures. The inserts have fastening means the fiber reinforcement helps to ensure their positioning during the injection of the polymer resin. The implementation of such a solution therefore involves the use of fiber reinforcement.
Un procédé de moulage d’une pièce comprenant au moins un insert partiellement surmoulé est connu du document WO20171 15026. Malheureusement, la solution proposée implique l’emploi de moules spécifiques présentant un système de positionnement et de maintien de l’insert dans le moule. Il serait intéressant de trouver des solutions plus simples pour maintenir un insert en position dans un moule lors de la fabrication d’une pièce. A molding process of a part comprising at least one partially molded insert is known from WO20171 15026. Unfortunately, the proposed solution involves the use of specific molds having a system for positioning and holding the insert in the mold. It would be interesting to find simpler solutions to maintain an insert in position in a mold during the manufacture of a part.
L’invention a pour objectif de répondre à au moins un des problèmes rencontrés dans l’art antérieur en proposant une nouvelle pièce hybride en matériau composite et comprenant au moins un insert métallique, ladite pièce comprenant au moins un insert configuré pour assurer lui-même son positionnement dans le moule d’injection. L’invention a également pour objectif de proposer un nouveau procédé de fabrication de telles pièces hybrides. Enfin l’invention concerne de nouveaux inserts métalliques fonctionnalisés en ce qu’ils comprennent des moyens de positionnement dans un moule, par exemple de moulage ou surmoulage par compression ou par injection. Par exemple, le moulage peut être fait par compression d’un mélange à mouler en feuille (SMC pour « Sheet Moulding Compound » en anglais), ou encore d’un matériau composite feutre de verre - matière thermoplastique (GMT pour « Glass Mat Thermoplastic » en anglais). The aim of the invention is to meet at least one of the problems encountered in the prior art by proposing a new hybrid part made of composite material and comprising at least one metal insert, said part comprising at least one insert configured to ensure itself. its positioning in the injection mold. The invention also aims to propose a new process for manufacturing such hybrid parts. Finally, the invention relates to novel functionalized metal inserts in that they comprise means for positioning in a mold, for example compression or injection molding or overmoulding. For example, the molding may be made by compression of a sheet molding compound (SMC), or a composite material glass felt - thermoplastic material (GMT for "Glass Mat Thermoplastic"). " in English).
A cet effet, l’invention a pour objet une pièce hybride pour véhicule automobile comprenant au moins un insert métallique surmoulé dans une couche de matériau plastique ou composite, l’insert comprenant un corps montrant une face supérieure et une face inférieure, et étant au moins en partie recouvert sur au moins une de ses faces par une couche dudit matériau plastique ou composite d’une épaisseur définie; la pièce étant remarquable en ce que l’insert comprend au moins un relief s’étendant depuis une de ses faces et en ce que la hauteur présentée par le ou les reliefs est inférieure ou égale à l’épaisseur de ladite couche de matériau plastique ou composite, surmoulée sur ladite face de l’insert. For this purpose, the subject of the invention is a hybrid part for a motor vehicle comprising at least one metal insert overmolded in a layer of plastic or composite material, the insert comprising a body showing an upper face and a lower face, and being at at least partially covered on at least one of its faces by a layer of said plastic or composite material of a defined thickness; the piece being remarkable in that the insert comprises at least one relief extending from one of its faces and in that the height presented by the relief or reliefs is less than or equal to the thickness of said layer of plastic material or composite, overmolded on said face of the insert.
Comme on l’aura compris à la lecture de la définition qui vient d’en être donnée, l’invention consiste à doter la pièce d’inserts fonctionnalisés présentant au moins un relief destiné à prendre appui sur la paroi du moule lors de l’opération de moulage de la pièce, incluant le surmoulage de l’insert. De préférence, le procédé de moulage mis en oeuvre est un procédé de moulage par injection. Le ou les reliefs vont faire office de cales assurant le positionnement de l’insert dans le moule selon une position prédéfinie. Une fois la pièce moulée, le ou les reliefs sont contenus dans l’épaisseur de la couche de matériau plastique ou composite surmoulée sur la face de l’insert d’où ils s’étendent. Selon un mode de réalisation préféré de l’invention, les reliefs présentés par l’insert ne sont pas destinés à dépasser de la couche de matériau plastique ou composite dans laquelle ils sont noyés. Ils sont destinés à y être intégralement contenus. As will be understood from reading the definition that has just been given, the invention consists in providing the piece with functionalized inserts having at least one relief intended to bear against the wall of the mold during the molding operation of the part, including overmoulding of the insert. Preferably, the molding method used is an injection molding process. The relief or reliefs will act as wedges ensuring the positioning of the insert in the mold according to a predefined position. Once the molded part, the relief or reliefs are contained in the thickness of the layer of plastic or composite material overmolded on the face of the insert from which they extend. According to a preferred embodiment of the invention, the reliefs presented by the insert are not intended to exceed the layer of plastic or composite material in which they are embedded. They are intended to be fully contained.
Selon des modes particuliers de réalisation, la pièce peut comprendre l’une ou l’autre des caractéristiques suivantes prises isolément ou selon toutes les combinaisons possibles : According to particular embodiments, the part may comprise one or the other of the following characteristics taken separately or in any combination possible:
Le ou au moins un des reliefs est intégralement contenu dans l’épaisseur de la couche de matériau plastique ou composite surmoulée sur ladite face de l’insert. The or at least one of the reliefs is integrally contained in the thickness of the layer of plastic or composite material overmolded on said face of the insert.
L’insert comprend au moins un relief s’étendant depuis chacune de ses faces inférieure et supérieure.  The insert comprises at least one relief extending from each of its lower and upper faces.
L’insert est un profilé comprenant au moins une face latérale et l’insert comprend au moins un relief s’étendant depuis la ou au moins une des faces latérales.  The insert is a profile comprising at least one lateral face and the insert comprises at least one relief extending from the or at least one of the lateral faces.
L’insert métallique comprend au moins trois reliefs non-alignés s’étendant depuis une de ses faces, de préférence depuis chacune de ses faces.  The metal insert comprises at least three non-aligned reliefs extending from one of its faces, preferably from each of its faces.
La hauteur présentée par le ou les reliefs, telle que mesurée depuis la face de l’insert de laquelle ils s’étendent, est égale à l’épaisseur de la couche de matériau plastique ou composite, surmoulé sur ladite face de l’insert.  The height presented by the relief or reliefs, as measured from the face of the insert from which they extend, is equal to the thickness of the layer of plastic or composite material, overmolded on said face of the insert.
Au moins un relief est combiné à une voie de fluage permettant le passage du matériau plastique ou composite au travers dudit insert lors de l’opération de surmoulage. L’insert comprend en outre au moins un trou de fluage permettant le passage du matériau plastique ou composite au travers de l’insert lors de l’opération de surmoulage.  At least one relief is combined with a creep path allowing the passage of the plastic or composite material through said insert during the overmolding operation. The insert further comprises at least one creep hole allowing the plastic or composite material to pass through the insert during the overmolding operation.
Le ou les reliefs se présentent sous forme de bosses, de nervures, de trous bordés, de pattes découpées et pliées depuis le corps de l’insert et/ou sous forme de bandes de tôle embouties découpées dans le corps de l’insert et présentant deux extrémités reliées audit corps.  The relief or reliefs are in the form of bumps, ribs, lined holes, tabs cut and folded from the body of the insert and / or in the form of stamped sheet metal strips cut into the body of the insert and having two ends connected to said body.
Le ou les reliefs se présentent sous forme de bosse associée à une voie de fluage, l’insert comportant une forme en creux sur la face opposée à celle comportant le relief, complémentaire à la forme de bosse, en vis-à-vis de ladite forme de bosse.  The relief or reliefs are in the form of a hump associated with a creep path, the insert having a recessed shape on the face opposite to that comprising the relief, complementary to the hump-shaped shape, vis-à-vis said hump shape.
Le ou les reliefs sont obtenus par déformation de la tôle formant le corps de l’insert, de sorte à former la forme en creux sur la face opposée à celle comportant le relief, de forme complémentaire à la forme de bosse, en vis-à-vis de ladite forme de bosse. The relief or reliefs are obtained by deformation of the sheet forming the body of the insert, so as to form the recessed shape on the face opposite to that comprising the relief, of shape complementary to the bump shape, vis-à-vis -vis of said form of hump.
Le ou les reliefs sont des zones bombées allongées. The relief or reliefs are elongated curved zones.
Une voie de fluage est disposée à l’une des extrémités de la zone bombée allongée. L’insert se présente sous forme d’une tôle métallique ou d’un profilé.  A creep path is disposed at one end of the elongated curved zone. The insert is in the form of a metal sheet or a profile.
La pièce hybride constitue un plancher de charge en matériau composite comportant une bordure métallique destinée à être soudée à la partie arrière du soubassement d’un véhicule automobile, de préférence la bordure métallique est une partie libre d’un insert métallique partiellement surmoulé dans le matériau composite dont est constitué le plancher. The hybrid part constitutes a load floor made of composite material comprising a metal edge intended to be welded to the rear part of the base. of a motor vehicle, preferably the metal edge is a free part of a metal insert partially overmolded in the composite material of which the floor is made.
Selon un deuxième aspect, l’invention a pour objet un véhicule, de préférence un véhicule automobile, remarquable en ce qu’il comprend au moins une pièce hybride telle que définie selon le premier aspect de l’invention. According to a second aspect, the subject of the invention is a vehicle, preferably a motor vehicle, which is remarkable in that it comprises at least one hybrid part as defined according to the first aspect of the invention.
Selon un troisième aspect, l’invention a pour objet un insert pour pièce hybride telle que définie selon le premier aspect de l’invention, l’insert comprenant un corps montrant une face supérieure et une face inférieure et étant remarquable en ce qu’il comprend au moins un relief s’étendant depuis une de ses faces, la hauteur dudit relief étant choisie en fonction de l’épaisseur de la couche de matériau plastique ou composite destinée à être surmoulée sur ladite face de l’insert, de sorte à être inférieure ou égale à l’épaisseur de ladite couche, de préférence l’insert se présente sous forme d’une tôle métallique ou d’un profilé. According to a third aspect, the subject of the invention is an insert for a hybrid part as defined according to the first aspect of the invention, the insert comprising a body showing an upper face and a lower face and being remarkable in that it comprises at least one relief extending from one of its faces, the height of said relief being chosen as a function of the thickness of the layer of plastic or composite material intended to be overmolded on said face of the insert, so as to be less than or equal to the thickness of said layer, preferably the insert is in the form of a metal sheet or a profile.
En particulier, l’invention a pour objet un insert pour pièce hybride telle que définie selon le premier aspect de l’invention, l’insert comprenant un corps montrant une face supérieure et une face inférieure et étant remarquable en ce qu’il comprend au moins un relief s’étendant depuis une de ses faces, et en ce qu’au moins un relief est combiné à une voie de fluage permettant le passage du matériau plastique ou composite au travers dudit insert lors d’une opération de surmoulage dudit insert. En d’autres termes, au moins un relief est associé, ou est adjacent, à une voie de fluage. In particular, the subject of the invention is an insert for a hybrid part as defined according to the first aspect of the invention, the insert comprising a body showing an upper face and a lower face and being remarkable in that it comprises less a relief extending from one of its faces, and in that at least one relief is combined with a creep path allowing the passage of the plastic or composite material through said insert during an overmolding operation of said insert. In other words, at least one relief is associated with, or adjacent to, a creep path.
Selon un quatrième aspect, l’invention a pour objet un procédé de fabrication d’une pièce hybride selon le premier aspect, ladite pièce hybride comprenant au moins un insert métallique au moins en partie surmoulé dans une couche de matériau plastique ou composite, le procédé utilisant un moule comprenant une partie inférieure et une partie supérieure, et comprenant les étapes suivantes : According to a fourth aspect, the subject of the invention is a method for manufacturing a hybrid part according to the first aspect, said hybrid part comprising at least one metal insert at least partially overmoulded in a layer of plastic or composite material, the process using a mold comprising a lower portion and an upper portion, and comprising the steps of:
mise en place du ou des inserts dans la partie inférieure du moule ;  placing the insert (s) in the lower part of the mold;
fermeture du moule par mise en position de la partie supérieure sur la partie inférieure ; et  closing the mold by positioning the upper part on the lower part; and
injection du matériau plastique ou composite dans le moule ;  injection of the plastic or composite material into the mold;
le procédé est remarquable en ce que l’insert ou au moins un des inserts comprend au moins un relief s’étendant depuis une de ses faces et en ce que : the method is remarkable in that the insert or at least one of the inserts comprises at least one relief extending from one of its faces and in that:
lors de l’opération de mise en place du ou des inserts dans le moule, ce ou ces derniers sont posés en appui contre la partie inférieure dudit moule par le ou les reliefs s’étendant depuis leur face inférieure disposée en regard de la partie inférieure du moule ; et/ou en ce que during the operation of placing the insert or inserts in the mold, this or these are placed in abutment against the lower part of said mold by the or the reliefs extending from their lower face arranged opposite the lower part of the mold; and / or in that
lors de la fermeture du moule, le ou les inserts sont en contact avec la partie supérieure du moule par le ou les reliefs s’étendant depuis leur face supérieure disposée en regard de la partie supérieure du moule.  when closing the mold, the one or more inserts are in contact with the upper part of the mold by the relief or reliefs extending from their upper face disposed facing the upper part of the mold.
De manière alternative, l’invention concerne un procédé de fabrication d’une pièce hybride telle que défini selon le premier aspect, ladite pièce hydride comprenant au moins un insert au moins en partie surmoulé par un ou plusieurs flans de mélange de moulage en feuille (SMC) ou de matériau composite feutre de verre - matière thermoplastique (GMT), le procédé utilisant un moule comprenant une partie supérieure et une partie inférieure et comprenant les étapes suivantes :  Alternatively, the invention relates to a method for manufacturing a hybrid part as defined according to the first aspect, said hybrid part comprising at least one insert at least partially overmolded by one or more blanks of sheet molding mixture ( SMC) or glass fiber composite material - thermoplastic material (GMT), the method using a mold comprising an upper part and a lower part and comprising the following steps:
mise en place du ou des inserts et du ou des flans de SMC ou de GMT dans la partie inférieure du moule, le ou au moins un des flans étant au contact de la face supérieure ou inférieure du ou d’au moins un des inserts ;  placing the insert (s) and the blank (s) of SMC or GMT in the lower part of the mold, the or at least one of the blanks being in contact with the upper or lower face of the or at least one of the inserts;
fermeture du moule par la mise en position de la partie supérieure sur la partie inférieure ;  closing the mold by placing the upper part on the lower part;
compression du ou des inserts et du ou des flans de SMC ou de GMT, de sorte que le ou au moins un des inserts est surmoulé par ledit ou lesdits flans ;  compression of the insert (s) and the blank (s) of SMC or GMT, so that the or at least one of the inserts is overmolded by said one or more blanks;
le procédé est remarquable en ce que l’insert ou au moins un des inserts comprend au moins un relief s’étendant depuis une de ses faces et en ce que : the method is remarkable in that the insert or at least one of the inserts comprises at least one relief extending from one of its faces and in that:
lors de la mise en place du ou des inserts dans le moule, ce ou au moins un de ces derniers est en appui contre le ou au moins un des flans de SMC ou de GMT par le ou les reliefs s’étendant depuis leur face inférieure, et/ou en ce que le ou au moins un des flans de SMC ou de GMT est en appui sur le ou au moins un des reliefs s’étendant depuis la face supérieure du ou d’au moins un des inserts.  when placing the insert or inserts in the mold, this or at least one of these is in abutment against the or at least one of the SMC or GMT blanks by the relief or reliefs extending from their underside , and / or in that the or at least one of the SMC or GMT blanks bears on the or at least one of the reliefs extending from the upper face of the or at least one of the inserts.
De préférence, l’invention concerne un procédé de fabrication d’une pièce hybride telle que définie selon le premier aspect, ladite pièce hydride comprenant au moins un insert au moins en partie surmoulé par un ou plusieurs flans de mélange de moulage en feuille (SMC), le procédé utilisant un moule comprenant une partie supérieure et une partie inférieure et comprenant les étapes suivantes : Preferably, the invention relates to a method for manufacturing a hybrid part as defined according to the first aspect, said hybrid part comprising at least one insert at least partially molded by one or more sheet molding mixture blanks (SMC ), the method using a mold comprising an upper portion and a lower portion and comprising the steps of:
mise en place du ou des inserts et du ou des flans de SMC dans la partie inférieure du moule, le ou au moins un des flans étant au contact de la face supérieure ou inférieure du ou d’au moins un des inserts ;  placing the insert (s) and the SMC blank (s) in the lower part of the mold, the or at least one of the blanks being in contact with the upper or lower face of the or at least one of the inserts;
fermeture du moule par la mise en position de la partie supérieure sur la partie inférieure, et chauffage dudit moule ; compression du ou des inserts et du ou des flans de SMC, entraînant le fluage du ou des flans de SMC sous l’effet de la pression et leur réticulation sous la température du moule de sorte que le ou au moins un des inserts est surmoulé par ledit ou lesdits flans ; closing the mold by positioning the upper part on the lower part, and heating said mold; compression of the insert (s) and the blank (s) of SMC, causing creep of the SMC blank (s) under the effect of the pressure and their crosslinking under the temperature of the mold so that the or at least one of the inserts is overmolded by said one or more blanks;
le procédé est remarquable en ce que l’insert ou au moins un des inserts comprend au moins un relief s’étendant depuis une de ses faces et en ce que : the method is remarkable in that the insert or at least one of the inserts comprises at least one relief extending from one of its faces and in that:
lors de la mise en place du ou des inserts dans le moule, ce ou au moins un de ces derniers est en appui contre le ou au moins un des flans de SMC par le ou les reliefs s’étendant depuis leur face inférieure, et/ou en ce que le ou au moins un des flans de SMC est en appui sur le ou au moins un des reliefs s’étendant depuis la face supérieure du ou d’au moins un des inserts.  when placing the insert or inserts in the mold, this or at least one of these is in support against the or at least one of the SMC blanks by the relief or reliefs extending from their underside, and / or or in that the or at least one of the SMC blanks bears on the or at least one of the reliefs extending from the upper face of the or at least one of the inserts.
Selon une variante, l’invention concerne un procédé de fabrication d’une pièce hybride telle que définis selon le premier aspect, ladite pièce hydride comprenant au moins un insert au moins en partie surmoulé par un ou plusieurs flans de matériau composite feutre de verre - matière thermoplastique (GMT), le procédé utilisant un moule comprenant une partie supérieure et une partie inférieure et comprenant les étapes suivantes : According to a variant, the invention relates to a method of manufacturing a hybrid part as defined according to the first aspect, said hybrid part comprising at least one insert at least partially molded by one or more blanks of composite glass felt material - thermoplastic material (GMT), the method using a mold comprising an upper part and a lower part and comprising the following steps:
chauffage du ou des flans de GMT ;  heating the blank (s) of GMT;
mise en place du ou des inserts et du ou des flans de GMT dans la partie inférieure du moule, le ou au moins un des flans étant au contact de la face supérieure ou inférieure du ou d’au moins un des inserts ;  placing the insert (s) and the blank (s) of GMT in the lower part of the mold, the or at least one of the blanks being in contact with the upper or lower face of the or at least one of the inserts;
fermeture du moule par la mise en position de la partie supérieure sur la partie inférieure, le moule n’étant pas chauffé ;  closing the mold by positioning the upper part on the lower part, the mold not being heated;
compression du ou des inserts et du ou des flans de GMT, entraînant le fluage du ou des flans de GMT sous l’effet de la pression de sorte que le ou au moins un des inserts est surmoulé par ledit ou lesdits flans ;  compression of the insert (s) and the blank (s) of GMT, resulting in creep of the blank (s) of GMT under the effect of pressure so that the or at least one of the inserts is overmolded by said blank or blanks;
le procédé est remarquable en ce que l’insert ou au moins un des inserts comprend au moins un relief s’étendant depuis une de ses faces et en ce que : lors de la mise en place du ou des inserts dans le moule, ce ou au moins un de ces derniers est en appui contre le ou au moins un des flans de GMT par le ou les reliefs s’étendant depuis leur face inférieure, et/ou en ce que le ou au moins un des flans de GMT est en appui sur le ou au moins un des reliefs s’étendant depuis la face supérieure du ou d’au moins un des inserts. the method is remarkable in that the insert or at least one of the inserts comprises at least one relief extending from one of its faces and in that: when placing the insert (s) in the mold, this or at least one of these is in abutment against the or at least one of the blanks of GMT by the relief or reliefs extending from their lower face, and / or in that the or at least one of the blanks of GMT is in support on the or at least one of the reliefs extending from the upper face of the or at least one of the inserts.
L’invention sera bien comprise et d’autres aspects et avantages apparaîtront clairement à la lecture de la description qui suit donnée en référence à la planche de dessins annexée sur laquelle : La figure 1 présente un exemple d’insert métallique selon l’invention. The invention will be well understood and other aspects and advantages will become clear from reading the following description given with reference to the attached drawing sheet in which: FIG. 1 shows an example of metal insert according to the invention.
Les figures 2 et 3 illustrent le positionnement de l’insert dans le moule et dans la couche de matériau polymère du fait des reliefs qu’il présente sur ses faces inférieure et supérieure.  Figures 2 and 3 illustrate the positioning of the insert in the mold and in the layer of polymeric material because of the reliefs it has on its lower and upper faces.
La figure 4 est une vue partielle d’un exemple de réalisation d’un insert selon l’invention présentant un panachage de reliefs et de trous de fluage. Les reliefs représentés se présentent sous forme de bandes de tôle embouties découpées dans le corps de l’insert et présentant deux extrémités reliées audit corps.  Figure 4 is a partial view of an embodiment of an insert according to the invention having a mixture of reliefs and creep holes. The reliefs shown are in the form of stamped sheet metal strips cut into the body of the insert and having two ends connected to said body.
La figure 5 est une vue partielle d’un exemple de réalisation d’un insert selon l’invention dont les reliefs se présentent sous forme de trous bordés.  Figure 5 is a partial view of an embodiment of an insert according to the invention, the reliefs are in the form of lined holes.
La figure 6 est une vue partielle d’un exemple de réalisation d’un insert selon l’invention dont les reliefs se présentent sous forme de pattes découpées et pliées depuis le corps de l’insert.  Figure 6 is a partial view of an embodiment of an insert according to the invention, the reliefs are in the form of tabs cut and folded from the body of the insert.
La figure 7 est une vue partielle d’un exemple de réalisation d’un insert selon l’invention dont les reliefs se présentent sous forme de bosse et sont associés à des trous de fluage.  Figure 7 is a partial view of an embodiment of an insert according to the invention, the reliefs are in the form of a bump and are associated with creep holes.
La figure 8 est une vue partielle d’un exemple de réalisation d’un insert selon l’invention dont les reliefs se présentent sous forme de bosses allongées, et comportant une voie de fluage à l’une des extrémités de ces bosses allongées.  Figure 8 is a partial view of an embodiment of an insert according to the invention, the reliefs are in the form of elongated bumps, and having a creep path at one end of these elongated bumps.
Dans la description qui suit, le terme « comprendre » est synonyme de « inclure » et n’est pas limitatif en ce qu’il autorise la présence d’autres éléments dans la pièce ou dans le véhicule auquel il se réfère et/ou d’autres étapes dans le procédé auquel il se réfère. Il est entendu que le terme « comprendre » inclut les termes « consister en ». Sur les différentes figures, les mêmes références désignent des éléments identiques ou similaires. Le terme « inférieur » désignera une proximité au sol plus importante que « supérieur » selon un axe vertical. On notera que dans le cadre de la description qui suit les faces inférieure et supérieure de l’insert sont définies par rapport à son positionnement dans le moule lors de la fabrication de la pièce hybride et non pas selon le positionnement futur de la pièce dans le véhicule. Dans le cadre de l’invention, le terme « résine » sera considéré comme synonyme de « matrice polymère ». In the following description, the term "understand" is synonymous with "include" and is not limiting in that it permits the presence of other elements in the room or in the vehicle to which it refers and / or other steps in the process to which it refers. It is understood that the term "understand" includes the words "consist of". In the different figures, the same references designate identical or similar elements. The term "lower" will mean a greater ground proximity than "higher" along a vertical axis. Note that in the context of the description which follows the lower and upper faces of the insert are defined with respect to its positioning in the mold during the manufacture of the hybrid part and not according to the future positioning of the part in the vehicle. In the context of the invention, the term "resin" will be considered synonymous with "polymer matrix".
L’invention concerne une pièce hybride pour véhicule automobile comprenant au moins un insert métallique surmoulé dans une couche de matériau plastique ou composite. Un exemple d’un tel insert 1 est représenté en figure 1 . Il s’agit d’un insert destiné à former le cadre d’un plancher de charge d’un véhicule automobile. Plus précisément il s’agit d’un embouti destiné à former la partie arrière du cadre d’un plancher (non représenté) en matériau plastique ou composite, de préférence en matériau composite. L’insert 1 représenté est destiné à n’être que partiellement surmoulé, de sorte à ce que le plancher formé présente une bordure 3 métallique pouvant être soudée aux éléments de soubassement d’un véhicule. Cette bordure métallique est dite libre en ce qu’elle n’est pas recouverte de matériau plastique ou composite. Néanmoins, l’invention peut s’adresser à d’autres types d’inserts et de pièces. L’invention est remarquable comme nous allons le voir en détail, en ce que l’insert 1 comprend au moins un relief 5 destiné à assurer son positionnement dans le moule lors de l’opération de surmoulage. A cet effet, l’insert 1 comprend au moins un relief 5 s’étendant depuis une de ses faces et en ce que la hauteur, présentée par le ou les reliefs 5, est inférieure ou égale à l’épaisseur de la couche de matériau plastique ou composite, surmoulée sur ladite face de l’insert 1. The invention relates to a hybrid part for a motor vehicle comprising at least one metal insert overmolded in a layer of plastic or composite material. An example of such an insert 1 is shown in FIG. It is an insert intended to form the frame of a load floor of a motor vehicle. More specifically it is a stamped to form the rear part of the frame of a floor (not shown) of plastic or composite material, preferably composite material. The insert 1 shown is intended to be only partially overmoulded, so that the formed floor has a border 3 metal which can be welded to the underbody elements of a vehicle. This metal edge is said to be free in that it is not covered with plastic or composite material. Nevertheless, the invention can be applied to other types of inserts and parts. The invention is remarkable as we will see in detail, in that the insert 1 comprises at least one relief 5 intended to ensure its positioning in the mold during the overmolding operation. For this purpose, the insert 1 comprises at least one relief 5 extending from one of its faces and in that the height, presented by the relief or reliefs 5, is less than or equal to the thickness of the layer of material plastic or composite, overmolded on said face of the insert 1.
De préférence, l’insert comprend un corps 9 se présentant sous forme d’une tôle métallique ou d’un profilé présentant une face inférieure et une face supérieure (7a, 7b illustrées sur la figure 2). Avantageusement, l’insert 1 comprend au moins trois reliefs 5 non-alignés sur au moins une de ses faces 7 et de préférence sur chacune de ses faces 7. En effet, dans une mise en oeuvre particulièrement préférée de l’invention, l’insert 1 comprend des reliefs 5 s’étendant depuis les deux faces supérieure et inférieure 7 de son corps 9. L’homme du métier aura avantage à ce que lesdits reliefs 5 montrent une hauteur similaire à celle de l’épaisseur du matériau plastique ou composite qui est surmoulée sur chacune des faces dudit insert 1 . Preferably, the insert comprises a body 9 in the form of a metal sheet or a profile having a lower face and an upper face (7a, 7b illustrated in Figure 2). Advantageously, the insert 1 comprises at least three reliefs 5 non-aligned on at least one of its faces 7 and preferably on each of its faces 7. Indeed, in a particularly preferred embodiment of the invention, the insert 1 comprises reliefs 5 extending from the two upper and lower faces 7 of its body 9. Those skilled in the art will have the advantage that said reliefs 5 show a height similar to that of the thickness of the plastic or composite material which is overmolded on each of the faces of said insert 1.
L’invention concerne également un procédé de fabrication, illustré en figures 2 et 3, d’une pièce hybride 1 1 comprenant au moins un insert 1 surmoulé dans une couche d’un matériau plastique ou composite, au moyen d’un moule comprenant une partie inférieure 13 et une partie supérieure 15. Le procédé comprenant les étapes suivantes : The invention also relates to a manufacturing method, illustrated in FIGS. 2 and 3, of a hybrid part 1 1 comprising at least one insert 1 overmolded in a layer of a plastic or composite material, by means of a mold comprising a lower part 13 and an upper part 15. The method comprising the following steps:
mise en place du ou des inserts 1 dans la partie inférieure 13 du moule ;  placing one or more inserts 1 in the lower part 13 of the mold;
fermeture du moule par mise en position de la partie supérieure 15 sur la partie inférieure 13; et  closing the mold by positioning the upper part 15 on the lower part 13; and
injection du matériau 17 plastique ou composite dans le moule ;  injection of the plastic or composite material 17 into the mold;
le procédé est remarquable en ce que l’insert ou au moins un des inserts comprend au moins un relief s’étendant depuis une de ses faces et en ce que : the method is remarkable in that the insert or at least one of the inserts comprises at least one relief extending from one of its faces and in that:
lors de l’opération de mise en place du ou des inserts 1 dans le moule, ce ou ces derniers sont posés en appui contre la partie inférieure 13 par le ou les reliefs 5a s’étendant depuis leur face inférieure 7a disposée en regard de la partie inférieure 13 du moule, et/ou en ce que  during the operation of placing one or more inserts 1 in the mold, this or these are placed in abutment against the lower part 13 by the relief or reliefs 5a extending from their lower face 7a disposed opposite the lower part 13 of the mold, and / or in that
lors de la fermeture du moule, le ou les inserts 1 sont en contact avec la partie supérieure 15 du moule par le ou les reliefs 5b s’étendant depuis leur face supérieure 7b disposée en regard de la partie supérieure 15 du moule. L’invention concerne aussi un procédé de fabrication d’une pièce hybride comprenant au moins un insert surmoulé par un ou plusieurs flans de SMC, au moyen d’un moule comprenant une partie supérieure et une partie inférieure. Le procédé comprend les étapes suivantes : mise en place du ou des inserts et du ou des flans de SMC dans la partie inférieure du moule, le ou au moins un des flans étant au contact de la face supérieure ou inférieure du ou d’au moins un des inserts ; when closing the mold, the one or more inserts 1 are in contact with the upper part 15 of the mold or the reliefs 5b extending from their upper face 7b disposed opposite the upper part 15 of the mold. The invention also relates to a method of manufacturing a hybrid part comprising at least one insert molded by one or more SMC blanks, by means of a mold comprising an upper part and a lower part. The method comprises the following steps: placing the insert (s) and the SMC blank (s) in the lower part of the mold, the or at least one of the blanks being in contact with the upper or lower face of the or at least one of the blanks one of the inserts;
chauffage et fermeture du moule par la mise en position de la partie supérieure sur la partie inférieure,  heating and closing the mold by placing the upper part on the lower part,
compression du ou des inserts et du ou des flans de SMC, entraînant le fluage du ou des flans de SMC sous l’effet de la pression et leur réticulation sous la température du moule, de sorte que le ou au moins un des inserts est surmoulé.  compression of the insert (s) and the blank (s) of SMC, causing creep of the SMC blank (s) under the effect of the pressure and their crosslinking under the temperature of the mold, so that the or at least one of the inserts is overmolded .
Le procédé est remarquable en ce que l’insert ou au moins un des inserts comprend au moins un relief s’étendant depuis une de ses faces et en ce que : lors de la mise en place du ou des inserts dans le moule, ce ou au moins un de ces derniers est en appui contre le ou au moins un des flans de SMC par le ou les reliefs s’étendant depuis leur face inférieure, et/ou en ce que le ou au moins un des flans de SMC est en appui sur le ou au moins un des reliefs s’étendant depuis la face supérieure du ou d’au moins un des inserts. The method is remarkable in that the insert or at least one of the inserts comprises at least one relief extending from one of its faces and in that: when placing the insert (s) in the mold, this or at least one of these is in abutment against the or at least one of the SMC blanks by the relief or reliefs extending from their lower face, and / or in that the or at least one of the SMC blanks is supported on the or at least one of the reliefs extending from the upper face of the or at least one of the inserts.
L’invention concerne en outre un procédé de fabrication d’une pièce hybride comprenant au moins un insert surmoulé par un ou plusieurs flans de GMT, au moyen d’un moule comprenant une partie supérieure et une partie inférieure. Le procédé comprend les étapes suivantes : chauffage du ou des flans de GMT ; The invention further relates to a method for manufacturing a hybrid part comprising at least one insert molded by one or more blanks of GMT, by means of a mold comprising an upper part and a lower part. The method comprises the following steps: heating the blank (s) of GMT;
mise en place du ou des inserts et du ou des flans de GMT dans la partie inférieure du moule, le ou au moins un des flans étant au contact de la face supérieure ou inférieure du ou d’au moins un des inserts ;  placing the insert (s) and the blank (s) of GMT in the lower part of the mold, the or at least one of the blanks being in contact with the upper or lower face of the or at least one of the inserts;
fermeture du moule par la mise en position de la partie supérieure sur la partie inférieure, le moule n’étant pas chauffé,  closing the mold by positioning the upper part on the lower part, the mold not being heated,
compression du ou des inserts et du ou des flans de GMT, entraînant le fluage du ou des flans de GMT sous l’effet de la pression, de sorte que le ou au moins un des inserts est surmoulé.  compression of the insert (s) and the blank (s) of GMT, causing the creep or blanks of GMT under the effect of pressure, so that the or at least one of the inserts is overmolded.
Le procédé est remarquable en ce que l’insert ou au moins un des inserts comprend au moins un relief s’étendant depuis une de ses faces et en ce que : lors de la mise en place du ou des inserts dans le moule, ce ou au moins un de ces derniers est en appui contre le ou au moins un des flans de GMT par le ou les reliefs s’étendant depuis leur face inférieure, et/ou en ce que le ou au moins un des flans de GMT est en appui sur le ou au moins un des reliefs s’étendant depuis la face supérieure du ou d’au moins un des inserts. The method is remarkable in that the insert or at least one of the inserts comprises at least one relief extending from one of its faces and in that: when placing the insert (s) in the mold, this or at least one of these is in support against the or at least one of the blanks of GMT by the reliefs extending from their lower face, and / or in that the or at least one of the GMT blanks bears on the or at least one of the reliefs extending from the upper face of the or at least one of the inserts .
Ainsi lorsque l’insert 1 présente des reliefs 5a sur sa face inférieure 7a destinée à être disposée en regard de la partie inférieure du moule 13, ou en regard d’un flan de SMC ou de GMT, et que ledit insert 1 est mis en place dans le moule, il va se poser en appui contre la paroi interne de la partie inférieure 13 du moule par le biais des reliefs 5a qui s’étendent depuis sa face inférieure 7a, ou contre la surface d’un flan de SMC ou de GMT. La présence d’au moins trois reliefs 5a non-alignés sur cette face inférieure 7a permet donc un appui stable et une orientation correcte de l’insert 1 dans le moule. Thus, when the insert 1 has reliefs 5a on its lower face 7a intended to be arranged facing the lower part of the mold 13, or facing a blank of SMC or GMT, and that said insert 1 is put into position. placed in the mold, it will rest against the inner wall of the lower part 13 of the mold through the reliefs 5a which extend from its lower face 7a, or against the surface of a blank of SMC or GMT. The presence of at least three non-aligned reliefs 5a on this lower face 7a thus allows a stable support and a correct orientation of the insert 1 in the mold.
Lorsque l’insert 1 présente des reliefs 5b sur sa face supérieure 7b destinée à être disposée en regard de la partie supérieure 15 du moule, ou en regard d’un flan de SMC ou de GMT, et que le moule est fermé, l’insert 1 sera en contact avec la paroi interne partie supérieure 15 du moule ou avec la surface d’un flan de SMC ou de GMT. When the insert 1 has reliefs 5b on its upper face 7b intended to be arranged facing the upper part 15 of the mold, or facing a blank of SMC or GMT, and the mold is closed, the insert 1 will be in contact with the inner wall of the upper part 15 of the mold or with the surface of a blank of SMC or GMT.
Préférentiellement, l’insert 1 présente des reliefs 5 sur ses deux faces inférieure 7a et supérieure 7b, si bien que la fermeture du moule va fixer en position l’insert 1 dans le moule, par exemple dans une position centrale selon la hauteur du moule. L’invention est remarquable en ce qu’elle n’a pas besoin que le moule soit doté de moyens de positionnement de l’insert 1 . Les moyens de positionnement dans le moule sont constitués par les reliefs 5 que l’insert 1 présente. Preferably, the insert 1 has reliefs 5 on its two lower faces 7a and 7b, so that the closing of the mold will fix in position the insert 1 in the mold, for example in a central position according to the height of the mold . The invention is remarkable in that it does not need the mold to be provided with means for positioning the insert 1. The positioning means in the mold are constituted by the reliefs 5 that the insert 1 has.
L’homme du métier aura avantage à ce que tous les reliefs 5 s’étendant depuis une des faces supérieure, inférieure, ou éventuellement latérale, de l’insert montrent une hauteur similaire. L’insert 1 sera alors positionné de sorte à ce que la face 7 portant lesdits reliefs 5 soit parallèle à la paroi du moule disposée en regard (ou d’un flan de SMC ou de GMT). Néanmoins, au besoin, l’homme du métier pourra privilégier une différence de hauteur entre reliefs d’une même face de l’insert en vue d’un positionnement oblique de l’insert 1 par rapport à au moins une des parois du moule et par conséquent à une des faces de la pièce, une fois moulée. Those skilled in the art will have the advantage that all the reliefs 5 extending from one of the upper, lower or possibly lateral faces of the insert show a similar height. The insert 1 will then be positioned so that the face 7 carrying said reliefs 5 is parallel to the facing wall of the mold (or a blank of SMC or GMT). Nevertheless, if necessary, the skilled person may prefer a difference in height between the reliefs of the same face of the insert in view of an oblique positioning of the insert 1 with respect to at least one of the walls of the mold and therefore to one of the faces of the piece, once molded.
Sur les figures 1 à 4, les reliefs 5 portés par l’insert 1 se présentent sous forme de bandes de tôle embouties 19 (voir figure 4) découpées dans le corps 9 de l’insert 1 et présentant deux extrémités reliées audit corps. Ce type de relief est avantageux en ce qu’il crée des zones de fluage 21 permettant le passage de la matière plastique ou composite au travers de l’insert, et favorise l’ancrage de l’insert 1 dans la pièce hybride. Les voies de fluage de la matière au travers de l’insert 1 et plus précisément de ses reliefs 5 sont illustrées sur les figures 2 et 3. Selon un mode de réalisation préféré de l’invention illustré à la figure 4, le corps 9 de l’insert 1 présente au moins un trou de fluage 23, ou ajourage, autorisant le passage du matériau plastique ou composite au travers de l’insert 1 lors de l’opération de surmoulage. Cette configuration est particulièrement utile pour assurer un bon ancrage de l’insert dans le matériau plastique qui le recouvre. Elle peut être adoptée que les reliefs présentent des voies de fluage de la matière associées, ou non. On voit que selon l’invention, l’insert peut présenter à la fois des voies de fluage 21 associées aux reliefs 5 et des trous de fluage 23 non-associés aux reliefs. In Figures 1 to 4, the reliefs 5 carried by the insert 1 are in the form of stamped sheet metal strips 19 (see Figure 4) cut into the body 9 of the insert 1 and having two ends connected to said body. This type of relief is advantageous in that it creates creep zones 21 allowing the passage of the plastic or composite material through the insert, and promotes the anchoring of the insert 1 in the hybrid part. The creep paths of the material through the insert 1 and more precisely of its reliefs 5 are illustrated in FIGS. 2 and 3. According to a preferred embodiment of the invention illustrated in Figure 4, the body 9 of the insert 1 has at least one creep hole 23, or ajourage, allowing the passage of plastic or composite material through the insert 1 during the overmolding operation. This configuration is particularly useful to ensure a good anchoring of the insert in the plastic material that covers it. It can be adopted that the reliefs have creep paths associated with the material, or not. It can be seen that according to the invention, the insert may have both creep paths associated with the reliefs 5 and creep holes 23 not associated with the reliefs.
De préférence, des voies de fluage 21 sont associées aux reliefs 5. L’opération de formation du ou des reliefs 5 va créer un trou 21 dans le corps 9 de l’insert 1 . Ceci est, par exemple, le cas lorsque la mise en forme des reliefs comprend des opérations de poinçonnage et ou de découpage de la tôle formant l’insert 1 . Par exemple, comme illustré sur la figure 5, le relief 5 peut être un trou bordé 25, c’est-à-dire un ajourage 27 entouré d’un rebord 29, le rebord 29 formant le relief 5 pour le positionnement de l’insert 1 . L’ajourage 27 formant la voie de fluage 21 associée au relief 5. Preferably, creep paths 21 are associated with the reliefs 5. The operation of forming the relief or reliefs 5 will create a hole 21 in the body 9 of the insert 1. This is, for example, the case when the shaping of the reliefs comprises punching operations and or cutting the sheet forming the insert 1. For example, as illustrated in FIG. 5, the relief 5 may be a bordered hole 25, that is to say an openwork 27 surrounded by a rim 29, the rim 29 forming the relief 5 for the positioning of the insert 1. The opening 27 forming the creep path 21 associated with the relief 5.
Selon un autre mode de réalisation illustré en figure 6, le relief 5 peut être constitué par une ou plusieurs patte 31 découpées dans la tôle formant le corps 9 de l’insert 1 et pliées. La voie de fluage 21 associée au relief 5 est constituée par l’ajourage 33 créé par le découpage-pliage de la ou desdites pattes 31. According to another embodiment illustrated in Figure 6, the relief 5 may be constituted by one or more lug 31 cut into the sheet forming the body 9 of the insert 1 and folded. The flow path 21 associated with the relief 5 is constituted by the openwork 33 created by the cutting-folding of the one or more lugs 31.
Selon autre mode de réalisation illustré en figure 8, le relief 5 est sous la forme d’une zone bombée allongée 45 s’étendant sur l’une des faces 7 de l’insert 1. La face de l’insert 1 opposée à celle comportant le relief 5, comporte une zone en creux 46 en vis-à-vis du relief 5, de forme complémentaire audit relief 5. La zone en creux 46 a donc aussi une forme allongée. Par exemple, la zone bombée allongée est sur la face 7a et la zone en creux 46 sur la face 7b. Le relief 5 est obtenu par exemple par déformation de la tôle formant le corps 9 de l’insert 1 , par exemple par emboutissage. La déformation de cette tôle formant le corps 9 crée sur l’une des faces de l’insert 1 la zone bombée allongée 45 et sur la face opposée dudit insert 1 la zone en creux 46. Une voie de fluage 21 est réalisée à l’une des extrémités de cette zone bombée allongée 45. Cette voie de fluage 21 peut être réalisée par exemple par un découpage de la tôle formant le corps 9, au moment de l’emboutissage de la tôle formant le corps 9 de l’insert, par exemple par poinçonnage. Comme le montre la figure 8, cette voie de fluage 21 forme une ouverture à l’extrémité de la zone bombée allongée 45, traversant l’insert 1 . C’est-à-dire que l’une des extrémités de la zone bombée allongée 45 débouche dans cette ouverture formant la voie de fluage 21 , la zone en creux 46 débouchant elle aussi à son extrémité dans cette même ouverture. Lors de la fabrication de la pièce hybride 1 1 , la zone en creux 46 permet de guider la matière plastique ou composite vers la voie de fluage 21 qui est associé au relief 5, en créant un canal orientant le déplacement de la matière plastique ou composite vers ladite voie de fluage 21 , lors du surmoulage de la matière plastique ou composite sur l’insert 1. L’insert 1 peut comporter plusieurs zones bombées allongées 45 sur l’une des faces 7a ou 7b de l’insert 1. En variante, des zones bombées allongées 45 sont disposées sur chacune des deux faces 7a et 7b de l’insert 1 , et l’insert 1 comportant donc aussi des zones en creux 46 sur chacune de ces faces 7a et 7b.According to another embodiment illustrated in FIG. 8, the relief 5 is in the form of an elongated curved zone 45 extending on one of the faces 7 of the insert 1. The face of the insert 1 opposite to that comprising the relief 5, has a recessed area 46 vis-à-vis the relief 5, complementary shape to said relief 5. The recessed area 46 also has an elongated shape. For example, the elongated curved area is on the face 7a and the recessed area 46 on the face 7b. The relief 5 is obtained for example by deformation of the sheet forming the body 9 of the insert 1, for example by stamping. The deformation of this sheet forming the body 9 creates on one of the faces of the insert 1 the elongated convex zone 45 and on the opposite face of said insert 1 the recessed zone 46. A creep channel 21 is formed at the one of the ends of this elongated curved zone 45. This creep path 21 can be made for example by cutting the sheet forming the body 9, at the time of stamping the sheet forming the body 9 of the insert, by example by punching. As shown in FIG. 8, this creep path 21 forms an opening at the end of the elongated convex zone 45, passing through the insert 1. That is to say that one of the ends of the elongated curved zone 45 opens into this opening forming the creep path 21, the hollow zone 46 also opening at its end in the same opening. During the production of the piece hybrid 1 1, the recessed area 46 guides the plastic or composite material to the creep path 21 which is associated with the relief 5, creating a channel directing the displacement of the plastic or composite material towards said flow path 21, during overmoulding of the plastic or composite material on the insert 1. The insert 1 may comprise several elongated curved zones 45 on one of the faces 7a or 7b of the insert 1. In a variant, elongated convex zones 45 are disposed on each of the two faces 7a and 7b of the insert 1, and the insert 1 also has recessed areas 46 on each of these faces 7a and 7b.
En variante non représentée, le relief 5 est sous la forme d’une moitié d’hémisphère, avec une voie de fluage 21 adjacent audit relief de sorte que le bord de l’hémisphère en saillie par rapport à l’insert 1 forme au moins une partie d’un des bords de ladite voie de fluage 21 . In a variant not shown, the relief 5 is in the form of a half hemisphere, with a creep path 21 adjacent to said relief so that the edge of the hemisphere protruding from the insert 1 forms at least part of one of the edges of said creep path 21.
Ces modes de réalisations peuvent être associés avec la présence de trous de fluage 23 dans l’insert 1 . These embodiments may be associated with the presence of creep holes 23 in the insert 1.
Selon une autre mise en oeuvre préférée de l’invention illustrée sur la figure 7, le ou les reliefs de l’insert 5 sont réalisés par emboutissage de sorte à ce que leur mise en forme ne crée pas de voie de fluage (ou trous) dans la tôle formant le corps 9 de l’insert. Les reliefs 5 peuvent se présenter sous forme de bosses 35 circulaires ou allongées, ou sous forme de nervures s’étendant sur tout ou partie de l’insert 1 selon n’importe quelle direction. Lorsque l’invention met en oeuvre de tels reliefs 5, l’homme du métier aura avantage à utiliser un insert 1 présentant également des trous de fluage 23. According to another preferred embodiment of the invention illustrated in FIG. 7, the relief or reliefs of the insert 5 are made by stamping so that their shaping does not create a creep path (or holes). in the sheet forming the body 9 of the insert. The reliefs 5 may be in the form of circular or elongate bumps, or in the form of ribs extending over all or part of the insert 1 in any direction. When the invention uses such reliefs 5, the skilled person will benefit from using an insert 1 also having creep holes 23.
Avantageusement et comme illustré sur les figures 2 et 3, la hauteur « h », présentée par le ou les reliefs 5 s’étendant depuis une face 7 de l’insert 1 , est égale à l’épaisseur « e » de la couche de matériau 17 plastique ou composite, surmoulée sur ladite face 7 de l’insert 1. Néanmoins, il peut arriver dans certains cas que lors de l’opération de surmoulage, le matériau (ou résine) injecté dans le moule s’infiltre entre le moule et les extrémités des reliefs 5 posées en appuis contre les parois du moule. Ainsi, selon une définition de l’invention, la hauteur « h » présentée par le ou les reliefs 5, telle que mesurée depuis la face 7 de l’insert 1 de laquelle ils s’étendent, correspond à au moins 90 % de l’épaisseur de la couche de matériau plastique ou composite, surmoulée sur ladite face 7 de l’insert, de préférence au moins 95 %, de préférence encore au moins 98%. En d’autres termes, la hauteur « h » présentée par le ou les reliefs 5, telle que mesurée depuis la face 7 de l’insert 1 de laquelle ils s’étendent, est inférieure ou égale à l’épaisseur « e » de la couche de matériau 17 plastique ou composite, surmoulée sur ladite face 7 de l’insert 1. L’invention permet de bénéficier de l’effet ressort de la tôle et ne nécessite pas un ajustage précis des côtes. Advantageously and as illustrated in Figures 2 and 3, the height "h", presented by the relief or reliefs 5 extending from a face 7 of the insert 1, is equal to the thickness "e" of the layer of plastic or composite material 17, overmolded on said face 7 of the insert 1. Nevertheless, it may happen in some cases that during the overmolding operation, the material (or resin) injected into the mold infiltrates between the mold and the ends of the reliefs 5 placed in support against the walls of the mold. Thus, according to a definition of the invention, the height "h" presented by the relief or reliefs 5, as measured from the face 7 of the insert 1 of which they extend, corresponds to at least 90% of the thickness of the layer of plastic or composite material overmolded on said face 7 of the insert, preferably at least 95%, more preferably at least 98%. In other words, the height "h" presented by the relief or reliefs 5, as measured from the face 7 of the insert 1 of which they extend, is less than or equal to the thickness "e" of the layer of plastic or composite material 17, overmolded on said face 7 of the insert 1. The invention makes it possible to benefit from the spring effect of the sheet and does not require precise adjustment of the ribs.
La pièce hybride 1 1 selon l’invention peut être réalisée en matériaux plastique ou en matériau composite, de préférence en matériau composite. Le matériau composite sélectionné peut être un matériau composite thermoplastique ou thermodurcissable. Les matériaux composites sont définis dans le cadre de l’invention comme présentant une matrice polymère et un ou plusieurs éléments de renforcement. Les éléments de renforcement comprennent ou sont constitués par des fibres ou un mélange de fibres sélectionnées parmi les fibres de verre, de carbone, de céramique, de graphite, naturelles telles que des fibres de lin, de chanvre ou de bambou, de polymères organiques tels que des fibres de polyester. De préférence les fibres des éléments de renforcement sont des fibres de verre. The hybrid part 1 1 according to the invention can be made of plastic materials or composite material, preferably composite material. The selected composite material can be a thermoplastic or thermosetting composite material. The composite materials are defined in the context of the invention as having a polymer matrix and one or more reinforcing elements. The reinforcing elements comprise or consist of fibers or a mixture of fibers selected from glass, carbon, ceramic, graphite, natural fibers such as flax, hemp or bamboo fibers, organic polymers such as than polyester fibers. Preferably the fibers of the reinforcing elements are glass fibers.
La matrice polymère thermoplastique sera avantageusement sélectionnée parmi un ou plusieurs matériaux choisis entre les polypropylènes (PP), les polyphtalamides (PPA), les polyétheréthercétones (PEEK), les polysulfures de phénylène (PPS), les polyamides-imide (PAI), les polyétherimides (PEI), les polyarylamides (PAA), ou les polyamides (PA) tel que par exemple du polyamide 6 (PA 6 ou polycaprolactame) ou du polyamide 6.6 (PA 6.6 ou polyhexaméthylène adipamide). The thermoplastic polymer matrix will advantageously be selected from one or more materials selected from polypropylenes (PP), polyphthalamides (PPA), polyetheretherketones (PEEK), phenylene polysulfides (PPS), polyamide imides (PAI), polyetherimides (PEI), polyarylamides (PAA), or polyamides (PA) such as for example polyamide 6 (PA 6 or polycaprolactam) or polyamide 6.6 (PA 6.6 or polyhexamethylene adipamide).
La matrice polymère thermodurcissable sera avantageusement sélectionnée parmi les polyesters insaturés, les polyuréthanes, les vinylesters ou les polyépoxydes. The thermosetting polymer matrix will advantageously be selected from unsaturated polyesters, polyurethanes, vinylesters or polyepoxides.
L’insert peut être totalement ou partiellement noyé dans le matériau plastique ou composite. Dans une mise en oeuvre préférée de l’invention, l’insert 1 est en partie surmoulé. Ainsi, préférentiellement, l’insert 1 présente une partie surmoulée sur au moins une de ses faces et une partie libre en ce qu’elle est non recouverte de matériau (ou résine). Avantageusement, la partie libre 3 et la partie destinée à être surmoulée sont agencées pour s’étendre perpendiculairement l’une par rapport à l’autre comme illustré sur les figures 1 , 3 et 4. The insert may be totally or partially embedded in the plastic or composite material. In a preferred embodiment of the invention, the insert 1 is partially overmolded. Thus, preferably, the insert 1 has a portion overmolded on at least one of its faces and a free portion in that it is not covered with material (or resin). Advantageously, the free part 3 and the part intended to be overmoulded are arranged to extend perpendicularly with respect to each other as illustrated in FIGS. 1, 3 and 4.
En effet, selon une mise en oeuvre préférée de l’invention (non représentée), la pièce hybride est un plancher de charge d’un véhicule automobile. De préférence, ledit plancher est en matériau composite. Par exemple, le plancher de charge est en polyester chargé en fibres de verre. Le plancher comprend avantageusement une bordure métallique destinée à être soudée à la partie arrière du soubassement du véhicule, comme c’est le cas pour les planchers de charge entièrement en métal. Cette bordure métallique est constituée par un ou plusieurs inserts selon l’invention, de sorte à ce que le ou les inserts soient partiellement surmoulés dans le plancher et présentent une partie noyée dans le matériau plastique ou composite et une partie externe destinée à être soudée. Indeed, according to a preferred embodiment of the invention (not shown), the hybrid part is a load floor of a motor vehicle. Preferably, said floor is made of composite material. For example, the load floor is polyester filled with fiberglass. The floor advantageously comprises a metal rim intended to be welded to the rear part of the underbody of the vehicle, as is the case for all-metal load floors. This metal edge is constituted by one or more inserts according to the invention, so that the inserts or are partially overmolded in the floor and have a portion embedded in the plastic or composite material and an outer portion to be welded.
Selon un mode de réalisation préféré de l’invention, le plancher de charge comprend une pluralité d’inserts, au moins un étant disposé sur chacun de ses bords. Le ou les inserts sont préférentiellement en acier et se présentent sous forme d’une tôle emboutie et/ou sous forme de profilés. L’insert peut également être en aluminium ou en magnésium. Par exemple, et tel que décrit dans le document WO2014/131967, les inserts forment un cadre. Les inserts disposés en partie avant et arrière du plancher sont des emboutis et les deux parties latérales sont des profilés. La partie du plancher arrière, en matériau composite uniquement présente des nervures de rigidification et éventuellement une cavité destinée à recevoir la roue de secours. According to a preferred embodiment of the invention, the load floor comprises a plurality of inserts, at least one being disposed on each of its edges. The insert or inserts are preferably made of steel and are in the form of a stamped sheet and / or in the form of profiles. The insert can also be aluminum or magnesium. For example, and as described in WO2014 / 131967, the inserts form a frame. The inserts arranged at the front and rear of the floor are stampings and the two side portions are profiles. The portion of the rear floor, composite material only has stiffening ribs and possibly a cavity for receiving the spare wheel.

Claims

REVENDICATIONS
1 . Pièce hybride (1 1 ) pour véhicule automobile comprenant au moins un insert (1 ) métallique surmoulé dans une couche de matériau (17) plastique ou composite, l’insert (1 ) comprenant un corps (9) montrant une face supérieure (7b) et une face inférieure (7a), et étant au moins en partie recouvert sur au moins une de ses faces (7a, 7b) par une couche dudit matériau (17) plastique ou composite d’une épaisseur définie; la pièce (1 1 ) étant caractérisée en ce que l’insert (1 ) comprend au moins un relief (5) s’étendant depuis une de ses faces (7a, 7b) et en ce que la hauteur présentée par le ou les reliefs (5) est inférieure ou égale à l’épaisseur de ladite couche de matériau plastique ou composite, surmoulée sur ladite face (7a, 7b) de l’insert (1 )· 1. Hybrid part (1 1) for a motor vehicle comprising at least one metal insert (1) overmolded in a layer of plastic or composite material (17), the insert (1) comprising a body (9) showing an upper face (7b) and a lower face (7a), and being at least partly covered on at least one of its faces (7a, 7b) by a layer of said plastic or composite material (17) of a defined thickness; the part (1 1) being characterized in that the insert (1) comprises at least one relief (5) extending from one of its faces (7a, 7b) and in that the height presented by the relief or reliefs (5) is less than or equal to the thickness of said layer of plastic or composite material, overmolded on said face (7a, 7b) of the insert (1) ·
2. Pièce hybride (1 1 ) selon la revendication 1 , caractérisée en ce que l’insert (1 ) comprend au moins un relief (5) s’étendant depuis chacune de ses faces inférieure (7a) et supérieure (7b) et/ou en ce que l’insert (1 ) métallique comprend au moins trois reliefs (5) non-alignés s’étendant depuis une de ses faces (7a, 7b), de préférence depuis chacune de ses faces (7a, 7b). 2. hybrid part (1 1) according to claim 1, characterized in that the insert (1) comprises at least one relief (5) extending from each of its lower faces (7a) and upper (7b) and / or in that the metal insert (1) comprises at least three non-aligned reliefs (5) extending from one of its faces (7a, 7b), preferably from each of its faces (7a, 7b).
3. Pièce hybride (1 1 ) selon l’une des revendications 1 ou 2, caractérisée en ce qu’au moins un relief (5) est combiné à une voie de fluage (21 ) permettant le passage du matériau plastique ou composite au travers dudit insert (1 ) lors de l’opération de surmoulage. 3. hybrid part (1 1) according to one of claims 1 or 2, characterized in that at least one relief (5) is combined with a creep channel (21) allowing the passage of plastic or composite material through of said insert (1) during the overmolding operation.
4. Pièce hybride (1 1 ) selon l’une des revendications 1 à 3, caractérisée en ce que l’insert (1 ) comprend en outre au moins un trou de fluage (23) permettant le passage du matériau plastique ou composite au travers dudit insert (1 ) lors de l’opération de surmoulage. 4. hybrid part (1 1) according to one of claims 1 to 3, characterized in that the insert (1) further comprises at least one creep hole (23) allowing the passage of plastic or composite material through of said insert (1) during the overmolding operation.
5. Pièce hybride (1 1 ) selon l’une des revendications 1 à 4, caractérisée en ce que le ou les reliefs (5) se présentent sous forme de bosses (35, 45), de nervures, de trous bordés (25), de pattes (31 ) découpées et pliées depuis le corps (9) de l’insert (1 ) et/ou sous forme de bandes (19) de tôle embouties découpées dans le corps (9) de l’insert (1 ) et présentant deux extrémités reliées audit corps (9). 5. hybrid part (1 1) according to one of claims 1 to 4, characterized in that the relief or reliefs (5) are in the form of bumps (35, 45), ribs, holes lined (25) , lugs (31) cut and folded from the body (9) of the insert (1) and / or in the form of strips (19) of stamped sheet metal cut into the body (9) of the insert (1) and having two ends connected to said body (9).
6. Pièce hybride (1 1 ) selon les revendications 3 et 5, caractérisé en ce que le ou les reliefs (5) se présentent sous forme de bosse (35, 45) associée à une voie de fluage (21 ), l’insert (1 ) comportant une forme en creux (46) sur la face opposée à celle comportant le relief (5), complémentaire à la forme de bosse (35, 45), en vis-à-vis de ladite forme de bosse (35, 45). 6. Hybrid part (1 1) according to claims 3 and 5, characterized in that the relief or reliefs (5) are in the form of a boss (35, 45) associated with a creep channel (21), the insert (1) having a recessed shape (46) on the face opposite to that having the relief (5), complementary to the bump form (35, 45), opposite said bump form (35, 45).
7. Pièce hybride (1 1 ) selon la revendication 6, caractérisée en ce que le ou les reliefs (5) sont obtenus par déformation de la tôle formant le corps (9) de l’insert (1 ), de sorte à former la forme en creux (46) sur la face opposée à celle comportant le relief (5), de forme complémentaire à la forme de bosse (35, 45), en vis-à-vis de ladite forme de bosse (35, 45). 7. hybrid part (1 1) according to claim 6, characterized in that the relief or reliefs (5) are obtained by deformation of the sheet forming the body (9) of the insert (1), so as to form the hollow shape (46) on the opposite side to that having the relief (5), of shape complementary to the bump form (35, 45), vis-à-vis said bump form (35, 45).
8. Pièce hybride (1 1 ) suivant la revendication 6 ou 7, caractérisé en ce que le ou les reliefs (5) sont des zones bombées allongées (45). 8. Hybrid part (1 1) according to claim 6 or 7, characterized in that the relief or reliefs (5) are elongated curved areas (45).
9. Pièce hybride (1 1 ) suivant la revendication 8, caractérisé en ce qu’une voie de fluage (21 ) est disposée à l’une des extrémités de la zone bombée allongée (45). 9. hybrid part (1 1) according to claim 8, characterized in that a creep path (21) is disposed at one end of the elongate curved zone (45).
10. Pièce hybride (1 1 ) selon l’une des revendications 1 à 9, caractérisée en ce qu’elle constitue un plancher de charge en matériau composite comportant une bordure métallique destinée à être soudée à la partie arrière du soubassement d’un véhicule automobile, de préférence la bordure métallique est une partie libre d’un insert métallique partiellement surmoulé dans le matériau composite dont est constitué le plancher. 10. Hybrid part (1 1) according to one of claims 1 to 9, characterized in that it constitutes a load floor composite material having a metal edge to be welded to the rear part of the underbody of a vehicle automobile, preferably the metal edge is a free portion of a metal insert partially overmolded in the composite material which is constituted the floor.
1 1 . Véhicule caractérisé en ce qu’il comprend au moins une pièce hybride (1 1 ) selon l’une des revendications 1 à 9. 1 1. Vehicle characterized in that it comprises at least one hybrid part (1 1) according to one of claims 1 to 9.
12. Insert (1 ) pour pièce hybride (1 1 ) selon l’une des revendications 3 à 9, l’insert comprenant un corps (9) montrant une face supérieure (7b) et une face inférieure (7a) et étant caractérisé en ce qu’il comprend au moins un relief (5) s’étendant depuis une de ses faces (7a, 7b), et en ce qu’au moins un relief (5) est combiné à une voie de fluage (21 ) permettant le passage du matériau plastique ou composite au travers dudit insert (1 ) lors d’une opération de surmoulage dudit insert (1 ). 12. Insert (1) for hybrid part (1 1) according to one of claims 3 to 9, the insert comprising a body (9) showing an upper face (7b) and a lower face (7a) and being characterized in that it comprises at least one relief (5) extending from one of its faces (7a, 7b), and in that at least one relief (5) is combined with a creep channel (21) allowing the passage of the plastic or composite material through said insert (1) during an overmolding operation of said insert (1).
13. Procédé de fabrication d’une pièce hybride (1 1 ) selon l’une des revendications 1 à 9, ladite pièce hybride (1 1 ) comprenant au moins un insert (1 ) métallique au moins en partie surmoulé dans une couche de matériau (17) plastique ou composite, le procédé utilisant un moule comprenant une partie inférieure (13) et une partie supérieure (15), et comprenant les étapes suivantes : mise en place du ou des inserts (1 ) dans la partie inférieure (13) du moule,13. A method of manufacturing a hybrid part (1 1) according to one of claims 1 to 9, said hybrid part (1 1) comprising at least one insert (1) metal at least partially overmolded in a layer of material (17) plastic or composite, the method using a mold comprising a lower part (13) and an upper part (15), and comprising the following steps: placing the inserts (1) in the lower part (13) of the mold,
- fermeture du moule par mise en position de la partie supérieure (15) sur la partie inférieure (13); et closing the mold by positioning the upper part (15) on the lower part (13); and
injection du matériau (17) plastique ou composite dans le moule ; le procédé est caractérisé en ce que l’insert (1 ) ou au moins un des inserts (1 ) comprend au moins un relief (5a, 5b) s’étendant depuis une de ses faces et en ce que :  injecting the plastic or composite material (17) into the mold; the method is characterized in that the insert (1) or at least one of the inserts (1) comprises at least one relief (5a, 5b) extending from one of its faces and in that:
lors de l’opération de mise en place du ou des inserts (1 ) dans le moule, ce ou ces derniers sont posés en appui contre la partie inférieure (13) dudit moule par le ou les reliefs (5a) s’étendant depuis leurface inférieure (7a) disposée en regard de la partie inférieure (13) du moule, et/ou en ce que  during the operation of placing the insert or inserts (1) in the mold, this or these are placed in abutment against the lower part (13) of said mold by the relief or reliefs (5a) extending from their surface lower part (7a) arranged facing the lower part (13) of the mold, and / or in that
lors de la fermeture du moule, le ou les inserts (1 ) sont en contact avec la partie supérieure (15) du moule par le ou les reliefs (5b) s’étendant depuis leur face supérieure (7b) disposée en regard de la partie supérieure (15) du moule.  when closing the mold, the one or more inserts (1) are in contact with the upper part (15) of the mold by the relief or reliefs (5b) extending from their upper face (7b) disposed opposite the part upper (15) of the mold.
14. Procédé de fabrication d’une pièce hybride selon l’une des revendication 1 à 9, ladite pièce hydride comprenant au moins un insert au moins en partie surmoulé par un ou plusieurs flans de mélange de moulage en feuille (SMC) ou de matériau composite feutre de verre - matière thermoplastique (GMT), le procédé utilisant un moule comprenant une partie supérieure et une partie inférieure et comprenant les étapes suivantes : mise en place du ou des inserts et du ou des flans de SMC ou de GMT dans la partie inférieure du moule, le ou au moins un des flans étant au contact de la face supérieure ou inférieure du ou d’au moins un des inserts ; 14. A method of manufacturing a hybrid part according to one of claims 1 to 9, said hybrid part comprising at least one insert at least partially molded by one or more blanks of sheet molding mixture (SMC) or material composite glass felt - thermoplastic material (GMT), the method using a mold comprising an upper part and a lower part and comprising the following steps: placement of the insert (s) and the blank (s) of SMC or GMT in the part bottom of the mold, the or at least one of the blanks being in contact with the upper or lower face of the or at least one of the inserts;
fermeture du moule par la mise en position de la partie supérieure sur la partie inférieure ;  closing the mold by placing the upper part on the lower part;
compression du ou des inserts et du ou des flans de SMC ou de GMT, de sorte que le ou au moins un des inserts est surmoulé par ledit ou lesdits flans ;  compression of the insert (s) and the blank (s) of SMC or GMT, so that the or at least one of the inserts is overmolded by said one or more blanks;
le procédé est caractérisé en ce que l’insert ou au moins un des inserts comprend au moins un relief s’étendant depuis une de ses faces et en ce que : lors de la mise en place du ou des inserts dans le moule, ce ou au moins un de ces derniers est en appui contre le ou au moins un des flans de SMC ou de GMT par le ou les reliefs s’étendant depuis leur face inférieure, et/ou en ce que le ou au moins un des flans de SMC ou de GMT est en appui sur le ou au moins un des reliefs s’étendant depuis la face supérieure du ou d’au moins un des inserts. the method is characterized in that the insert or at least one of the inserts comprises at least one relief extending from one of its faces and in that: when placing the insert or inserts in the mold, this or at least one of these is in abutment against the or at least one of the SMC or GMT blanks by the relief or reliefs extending from their underside , and / or in that the or at least one of the SMC or GMT blanks bears on the or at least one of the reliefs extending from the upper face of the or at least one of the inserts.
EP19700525.9A 2018-01-18 2019-01-17 Hybrid part made of composite material comprising at least one metal insert and method for manufacturing such a part Pending EP3740366A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR1850412A FR3076757B1 (en) 2018-01-18 2018-01-18 HYBRID PART OF COMPOSITE MATERIAL COMPRISING AT LEAST ONE METAL INSERT AND METHOD FOR MANUFACTURING SUCH A PART.
PCT/EP2019/051098 WO2019141754A1 (en) 2018-01-18 2019-01-17 Hybrid part made of composite material comprising at least one metal insert and method for manufacturing such a part

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EP3740366A1 true EP3740366A1 (en) 2020-11-25

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US (1) US12083720B2 (en)
EP (1) EP3740366A1 (en)
CN (1) CN214773523U (en)
FR (1) FR3076757B1 (en)
WO (1) WO2019141754A1 (en)

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FR3125248B1 (en) * 2021-07-16 2024-02-23 Cie Plastic Omnium Se Process for molding a motor vehicle part comprising a metal insert

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US5672405A (en) * 1996-02-26 1997-09-30 Plank, Jr.; J. Lee Metal-reinforced molded-plastic composite structures
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FR3076757B1 (en) 2019-12-13
WO2019141754A1 (en) 2019-07-25
CN214773523U (en) 2021-11-19
US12083720B2 (en) 2024-09-10
US20210170646A1 (en) 2021-06-10
FR3076757A1 (en) 2019-07-19

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