KR20020053092A - Plastic composite unit - Google Patents

Abstract

The present invention relates to plastic composites consisting of different materials, for example metals and plastics, and two or more flat materials made of different metals or plastics. The materials of the invention are connected to each other at their edges, and the connections are made of thermoplastic material formed thereon.

Description

Plastic Composite {PLASTIC COMPOSITE UNIT}

The present invention is characterized in that the edges are made of different materials, for example metals and plastics, and two or more flat materials made of different metals or different plastics, the connections of which are made of molded-on thermoplastics. It relates to a plastic composite.

Positive-fit connections of plate materials made of different materials are obtained by molding thermoplastics.

Complexes meet different technical functions in different fields. For example, the composite combines a high strength heat resistant member and a member suitable for cathodic electrodeposition coating with a material of made-to-measure to be a functional area.

The composite products or semi-finished products actually used consist of, for example, flat composites, which are sandwiched by a plastic or plastic foam sandwiched between two metal sheets, for example (EP 489 320 A1, EP 285 974 A1). And EP 547 664 A2). Also known are methods for the production of composite sheets having an outer metal sheet and an inner rib structure (see EP 775 573 A2). It is also known to join metal sheets by combining compression and injection molding in a mold (see EP 721 831 A1). In addition, plastic / metal composites in which the metal sheet is supported by the rib structure are known (see EP 370 342 A3).

The composites and composite semifinished products described in the prior art and literature are designed to achieve uniformly high strength and hardness, or sound insulation and heat dissipation, in the entire member.

However, in certain special applications, for example, the sheet must meet different technical requirements at its different sites. This may mean that on one half of the sheet an insulating function is required and to be achieved on the other half of the same member with respect to the boundary of the other separate member or structural member or opening. For example, if a conventional composite sheet is used in the above case, the whole member is subjected to excessive conditions in terms of its function and thus becomes too difficult or complicated to manufacture.

It is therefore an object of the present invention to provide a composite of the type mentioned in the introduction, which combines the properties of a particular acoustic, mechanical, optical or other material required for the function of the member to be met in each case at various parts of the member. .

The object according to the invention is achieved by providing a member consisting of two or more different sites made of different materials joined to mold the thermoplastic to form a positive fixation.

The present invention consists of two or more flat materials made of different materials, in particular different metals, different plastics, or metals and plastic parts, to which the edges are joined, the joints consisting of molded, in particular injection molded thermoplastics, in particular one or more The plastic composite is characterized in that the material is surrounded or pierced with thermoplastic material at the edges of the joint to form a positive fixation.

Suitable high strength metal materials include steel, aluminum, magnesium. The material may be made of ceramic, thermosetting resin or plastic composite material.

Thermoplastic materials suitable both for the material and for the joints are optionally filled plastics of unreinforced or reinforced, such as polyamides, in particular polyamide-6, polyamide-6.6, polyamide-12, polyamide-11 or poly Esters, in particular polyethylene terephthalate, polybutylene terephthalate, or polyolefins, in particular polypropylene, styrene copolymers, especially SAN resins or ABS, or polycarbonates, polypropylene oxides, polyphenylene sulfides, polyimides, PSOs or PEEK, or possible mixtures of these plastics.

The composite is a flat plate hybrid member comprising mainly linear or point functional members. A joining site of a desired structure is provided at a joining portion to be joined with another member, and the joining site can be variously designed in view of shape, position and size, and material.

In a preferred type of composite, one or more materials of the composite have perforations or depressions in the joint, through which injection molded thermoplastic material penetrates to form positive fixed connections of the materials.

One particularly preferred embodiment of the composite is characterized in that one of the materials consists of the same thermoplastic as the joint.

In a preferred embodiment, one of the materials consists of an elastomer, in particular a thermoplastic elastomer. Such a member can be obtained, for example, by generally known two-component injection molding.

Elastomers are preferably thermoplastic polyolefins and thermoplastic polyurethanes.

In a preferred embodiment of the present invention, if necessary, one of the materials of the electromagnetic shielding member is made of a metal further bonded to a nonmetallic material.

The material of the composite according to the invention, which is connected to a structure different from the composite, or to another member, can be freely selected according to the bonding or connecting method suitable thereto.

If the plastic composite according to the invention is for example welded with a steel frame, the material joining the frame should be weldable sheet steel.

According to the above it is possible to fix the entire plastic composite according to the invention to the outer member or to the structural member at various locations by completely different bonding methods, for example metal welding and plastic friction welding.

The invention also provides the use of plastic composites as machines and vehicles, in particular automobiles, electronics, household products or building necessities.

The materials of the invention are joined together in the form of metal sheets, panels, sheets, profiles (open or closed profiles) or hollow chambers. The type, type and number of materials can vary as desired. In a preferred embodiment, flat materials, such as metal sheets and plastic sheets, are joined to each other at their edges to form a positive fixation. For this purpose a rivet head made of thermoplastic material which allows for strong connection to a high strength material (for example a metal sheet) is molded in the overlapping hole area of the joint.

In this way, several high strength materials can be bonded to each other. The function of plastic can be limited to the bonding of high strength materials in the form of rivet heads.

In addition, there is a possibility to produce composites of several high strength materials which are likewise bonded directly to one another, which are secured by plastic rivet connections, but the plastic member also has other functions, for example in the form of molded plastic sheets.

By attaching a flexible member made of a flexible thermoplastic, thermoplastic elastomer or elastomer between the high strength, inflexible or hard portions of the composite, the dynamic properties of the entire member are improved or the assembly of the member is facilitated. In addition, the member can be partially moved by devising the flexible material as the film hinge.

In some areas of the member, metal sheets can be used to block electromagnetic waves as a material bonded to a non-conductive material, such as a thermoplastic or other non-metallic material.

Any joining of the member according to the invention to another member or structure can be carried out on all generally known materials due to the positive fixed connection of the individual materials. The joining method can be selected arbitrarily.

High heat resistant plastics (polyamide, polybutylene terephthalate, polyethylene terephthalate, polypropylene oxide, PSO, polyphenylene sulfide, polyimide, PEEK of non-reinforced or non-filled and fiber-reinforced or filled structure) Or a mixture of the above materials), it is possible to obtain excellent heat resistance and suitability of the composite for negative electrodeposition coating together with positive fixed bonding of the materials.

Composites can be prepared in a variety of ways. For example, the connection form of plastic and high-strength member (metal material) is mainly different:

1. Positive fixed connection of plastic material and high strength material by material formation

In the manufacturing method, the connecting part can be obtained by any of plastic injection molding and riveting by a preformed connecting member. In both cases, the high-strength material has holes in the edges of the joints (for example metal sheets with holes bored in the edges), through which thermoplastics pass and a positive fixed connection is achieved.

In the case of connection by injection molding, for example, the metal sheet is first inserted into the injection mold. As a result of the injection molding process, a less strong material, for example in the form of a sheet, is obtained and a connection with the metal sheet is achieved. As the plastic material is introduced in liquid form into the injection mold, it can flow through holes in the metal sheet to form rivet heads opposite the metal sheet. In this way, various parts or composite materials made of metal can be bonded to one another in a single process by means of sites directly or indirectly made of thermoplastics.

In a similar manner, less strong materials can also be secured to high strength materials using plastic riveting. In this case, the thermoplastic material is first injected individually into the injection mold without a metal sheet, but with a molded joint stud. One or more metal sheets are then laminated to the plastic part, and the bonding studs protrude through holes made in the metal sheet (s). The bonding studs are then molded into rivet heads by a molding process (eg ultrasonic welding). In addition, welded joining can be accomplished using separate auxiliary members (eg stud welding) or by joining two thermoplastic materials with a molded joining member.

2. Positive fixed connection by snap connection of thermoplastic and high strength materials. In this method, the plastic material to which the essential snap member is fixed is first produced. For example, injection molded plastic parts having molded studs inserted through manufactured holes of high strength materials can be used for this purpose.

Another possibility of joining the workpiece consists in the use of various combinations of the methods described above. Thus, it is possible to attach the same bead to two parts and to positively connect between high strength materials. Rivet joints can be attached by additional identical holes in the two high strength materials, for example by forming molded studs in plastic parts.

The advantages obtained with the present invention can be summarized as follows.

The composite makes it possible to obtain a flat composite consisting of the material of the material which can vary as desired.

It is possible to devise composites with partially different properties and stress levels to meet special requirements.

The present invention enables the design of composites having partially different ranges of properties at optimal cost and weight.

The invention also makes it possible to freely choose a joining method for joining with other members and structural members, and to produce flat composites from different materials in a single process.

Suitably designed composites according to the invention have a variety of uses as machines, vehicles and all kinds of members, in particular as automobiles, electronics, household products and building necessities.

Particularly suitable applications for the composite include structural materials for automobiles, doors, bumpers, supports, front and rear parts for passenger vehicles, side sill frames and decorative members with increased strength with other material properties.

The present invention is described in more detail below with reference to the drawings.

1 shows a sheet 1 made of a thermoplastic material in which a steel sheet 2 is fixed by a positive fixed connection.

2 shows the connection of two high strength materials by medium-strength materials made of plastic.

3 shows the connection of several metal sheets by one material made of thermoplastic polyurethane.

4 shows the lower part in the tunnel part of the motor vehicle in detail.

5 shows a cross-sectional view of a composite of three metal sheets with turning.

Example 1

Plate composite with partially different functions (FIG. 1)

FIG. 1 shows a sheet 1 made of thermoplastic material, in which a steel sheet 2 is fixed at the left end by a positive fixed connection 6 to absorb concentrated forces. The upper side of the left half of the sheet 1 is provided with a foam 3 for sound insulation. In the right half of the sheet 1, the sheet 1 is formed of two basic U-shaped profiles 5 made of aluminum and an integrated rib structure made of the same material as the sheet 1 for absorbing relatively large flat loads ( 4) is supported by. In this case, the sheet 1, the lip structural member 4 and all the positive fixed connecting portions 6 of the joint portion are formed by the thermoplastic member.

Composites can be prepared in two different ways. On the other hand, the metal sheet 2, the foam 3 and the U-shaped profile 5 are put in a suitably molded injection mold, and then the resin member is injected to fix the sheet 1, the lip structure 4 and the positive fixing. It is possible to manufacture the connection 6. When the melt solidifies during the injection molding process, the individual members are strongly bonded to each other. In the second variant, the sheet 1 with the studs required for the integrated lip structure 4 and the positive fixed connection 6 is initially produced. The sheet comprising the metal sheet 2, the foam 3 and the U-shaped profile 5 is then fitted so that the studs of the sheet 1 fit into the prepared holes of the members 2, 3 and 5. Is placed in (1). The stud is then formed into the positive fixed connection 6 by ultrasonic welding.

Example 2

Cross section of the composite made of three metal sheets (FIG. 2)

2 shows how different high strength materials (metal sheets) are directly bonded to each other. Turning 11 is provided at the edge of the metal sheet 2 so that the metal sheets 2 and 10 are joined to each other to form a positive fixation. Positive fixed connections of different metal sheets are secured by enclosing the joint with the thermoplastic member 15 by injection molding.

Example 3

Cross section of flexible composite made from metal sheet and thermoplastic member (FIG. 3)

In this embodiment, the two metal sheets 2 are joined to each other in a flexible manner by the elastic sheet 9 made of thermoplastic polyurethane. The connection is formed by a positive fixed connection 6 made of the same material as the sheet 9 according to the description of the embodiment 1 or 2. The additional metal sheet 12 is connected to the other side of the composite by a thermoplastic member 16 made of a rigid plastic material. The elastic sheet 9 and the thermoplastic member 16 can be molded to the metal sheet introduced into the injection mold in one step by two-component injection molding.

Example 4

Sectional view of the underside of the vehicle (Figure 4)

4 shows a cross section of the lower body within the tunnel portion of the vehicle. The floor panel 2, the tunnel metal sheet 7 and the tunnel sheath 8 are each made of steel and joined to each other by thermoplastic material 17. The workpieces 2 and 7 are introduced into the injection mold and partially overlap with the thermoplastic at their edges. The joining studs are molded in a later work at the same time after the tunnel cover 8 is laid and molded into the rivet connection 6 by ultrasonic welding.

According to the method, the floor panel of the vehicle may likewise be joined to the fender, or the side member of the threshold portion may be joined to the floor panel.

Example 5

Cross section of the composite made of three metal sheets (FIG. 5)

5 shows how different high strength materials (metal sheets) can be directly bonded. Turning 51 is provided at the edges of the metal sheets 52 and 10 so that the metal sheets 52 and 10 are joined to each other to form a positive fixation. The positive fixed connection of the different metal sheets 52 and 10 is fixed by injection molding so as to surround the connection with the thermoplastic member 55.

Claims (8)

It consists of two or more flat materials (1) and (2) made of different materials, in particular different metals, different plastics or metals and plastic parts, with edges 13 joined to each other, the joints 6 being molded-on ), In particular injection molded thermoplastic material, in particular one or more materials (1) or (2) are perforated or surrounded by thermoplastic material at the edges (13) of the joint (6) to provide a positive-fit connection. Plastic composite, characterized in that. 2. Plastic composite according to claim 1, characterized in that at least one material of the composite has perforations or depressions penetrating with thermoplastic material in the edges (13) of the joints (6) to form positive fixed connections of the material. The plastic composite according to claim 1 or 2, wherein any one of the materials (1) consists of the same thermoplastic material as the joints (6). Plastic composite according to any one of the preceding claims, characterized in that any one of the materials (1) consists of an elastomer, in particular a thermoplastic elastomer. 5. The plastic composite of claim 4 wherein the elastomer is a thermoplastic polyolefin or a thermoplastic polyurethane. The plastic composite according to any one of claims 1 to 5, wherein any one of the electromagnetic wave shielding materials (2) is made of a metal, and the metal is bonded to the nonmetallic material (1). The method of claim 1, wherein the thermoplastic material is selected from polyamide, polyester, polyolefin, styrene copolymer, polycarbonate, polypropylene oxide, polyphenylene sulfide, polyimide, PSO and PEEK, And a possible mixture of these polymers. Use of the plastic composite according to any one of claims 1 to 7 as a structural material for machines and vehicles, in particular automobiles, electronics, household products or building necessities.