WO2003006834A1 - Procede de fabrication de pieces composites en metal et plastique, pieces composites concernees - Google Patents

Procede de fabrication de pieces composites en metal et plastique, pieces composites concernees Download PDF

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Publication number
WO2003006834A1
WO2003006834A1 PCT/EP2002/007410 EP0207410W WO03006834A1 WO 2003006834 A1 WO2003006834 A1 WO 2003006834A1 EP 0207410 W EP0207410 W EP 0207410W WO 03006834 A1 WO03006834 A1 WO 03006834A1
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WO
WIPO (PCT)
Prior art keywords
joining
joining tool
plastic structure
composite
metal
Prior art date
Application number
PCT/EP2002/007410
Other languages
German (de)
English (en)
Inventor
Wolfgang Wilhelm
Original Assignee
Basf Aktiengesellschaft
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 Basf Aktiengesellschaft filed Critical Basf Aktiengesellschaft
Publication of WO2003006834A1 publication Critical patent/WO2003006834A1/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
    • F16B5/04—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of riveting
    • F16B5/045—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of riveting without the use of separate rivets
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/64—Joining a non-plastics element to a plastics element, e.g. by force
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
    • B29C65/7437—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc the tool being a perforating tool
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81411—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81415—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being bevelled
    • B29C66/81417—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being bevelled being V-shaped
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • 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
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0045—Perforating
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • 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

Definitions

  • the invention relates to a method for producing a composite component from a metal component and a plastic structure, these composite components and their use as components or component components in automobile, aircraft or shipbuilding or in the production of furniture, household or electrical appliances.
  • Composite molded parts made of metal and plastic are known to the person skilled in the art and are used, among other things. as so-called hybrid components in automotive engineering, e.g. in the form of front-end modules.
  • the combination of metal and plastic makes it possible to produce products with low weight, great rigidity and high resilience at low cost.
  • the molded plastic part can also be used to integrate additional functions such as hinge parts, bearing points, cable clamps or snap and screw connections into the component at an early stage in the manufacturing process.
  • a method for producing such composite molded parts is e.g. in the published patent application EP-A 0 370 352, according to which a thin sheet of metal provided with passages is inserted into a shell-shaped injection mold and the melt-shaped plastic is injected accordingly.
  • This process is very complex and prone to wear. It requires a lot of effort in terms of tool maintenance. A high proportion of rejects can often not be avoided.
  • a new, mostly complicated injection molding tool is required for each new model variant or change. Series production is therefore often associated with unpredictable risks.
  • connection techniques are described in the as yet unpublished European patent application with the file number 00119476.0. This should lead to a lower proportion of product waste. For example, the partial or full-surface bonding of metal and plastic in the contact areas, the subsequent formation of plastic rivets by melting in the openings in the metal sheet, the connection with screws or snap hooks, and the joining together by flanging flaps on the metal sheet or disclosed at the edges or openings of the plastic structure.
  • these connection techniques either make use other materials, such as adhesives or screws, or additional process steps required.
  • a method for producing a composite component from at least one metal component and at least one plastic structure in which the metal component and the plastic structure are positively placed on or against one another at the point to be joined, optionally locked, and at least one deformation-resistant joining tool is attached to the or the Joints through the metal component and through or at least into the plastic structure and this is removed by a counter-movement again from the recess or opening of the composite component formed.
  • the metal component and plastic structure are in a form-fitting manner on or on top of each other before joining, at least in the area of the joining point.
  • the composite of metal component and plastic structure that has not yet been joined is preferably locked during the joining process, for example with the aid of a tool, so that these component components do not move against one another during joining.
  • Methods and tools known to the person skilled in the art for example presses, clamps, clips or collets, can be used for the purpose of locking.
  • the metal component and plastic structure can also be partially or completely glued together before joining.
  • the joining process takes place in such a way that a deformation-resistant or rigid joining tool is driven at the joint through the adjacent surface of the metal component in or, depending on the thickness of the plastic structure at the joint or the length of the joining tool, through this plastic structure.
  • a positive and non-positive connection is achieved in the method according to the invention in that the metal surface is broken open by the joining tool and the metal edge that forms usually penetrates into the immediately adjacent plastic structure, the walls of the joining tool pressing the metal edge that forms on the plastic structure. If the joining tool also penetrates the plastic structure, the composite structure regularly has an opening at the joining point.
  • the plastic structure at least in the area of the joint, has a temperature above room temperature, i.e. temperature above about 25 ° C.
  • temperatures can also be selected that are just below the melt temperature of the underlying plastic material.
  • the entire plastic structure or the composite of metal component and plastic structure can also have such an elevated temperature.
  • Common methods and heaters can be used to heat the plastic structure and / or metal component. Local or localized heating is possible e.g. by means of laser radiation or ultrasound. Accordingly, with the method proposed according to the invention, both conventional plastic structures, that is to say those which have ambient temperature, and freshly injected tool-falling parts which have an elevated temperature and are therefore generally still relatively soft, but also post-tempered plastic structures, i.e. Those that have been brought to an elevated temperature shortly before joining are joined to form a positive connection with a metal component.
  • the joining tool can have a temperature above room temperature during the joining process.
  • the former can be removed from the joint again by means of a relative movement of the joining tool and the composite component, and a wiper can also be used to support the opposite movement. If, for example, the joining tool is withdrawn from the recess formed, a scraper which is advantageously positioned in the region of the joining point can help that the composite component and the possibly jammed joining tool can be separated again.
  • the stripper can, for example, also completely or partially surround the joining tool in the form of a cylinder or in any other desired geometry, the joining tool being able to move up and down in the stripper.
  • the joining process can be carried out manually, semi-automatically or fully automatically.
  • Several joining tools can be driven into the composite structure simultaneously or in chronological order at different joining points.
  • One or more joining tools can also be part of a machine tool with which the joining tools can be used in any arrangement or in different time sequences.
  • the joining tool is suitably driven into the composite structure perpendicularly or almost perpendicularly to the joining surface.
  • Two or more joining tools can furthermore be aligned parallel or almost parallel during the joining process for producing a composite component. At least two joining tools are preferably not aligned parallel to one another in the joining process with respect to a flat metal component surface.
  • the penetration or penetration process of the joining tool and / or the process of separating the joining tool and the composite component can be superimposed by a rotational movement of the joining tool about its longitudinal axis.
  • the rotational movements when penetrating or penetrating and separating when the joining tool has a thread structure run in opposite directions.
  • Another embodiment of the method according to the invention comprises a wobble, pendulum or gyroscopic movement of the joining tool when the composite structure penetrates or penetrates, but in particular when or after reaching the maximum penetration or Penetration depth, that is, when recording or during the opposite movement.
  • these are the movements of the joining tool in which the longitudinal axis of the joining tool is brought out of its original joining direction.
  • This wobble, pendulum or gyroscopic movement can also be maintained when the joining tool is removed from the recess or the opening in the composite component.
  • the longitudinal axis of the joining tool can, for example, describe the shape of a cylinder, a single or double cone or two triangles pointed to one another.
  • the aforementioned wobble, pendulum or gyroscopic movements of the joining tool are suitable for producing an undercut in one work step, ie together with the joining process.
  • the joint can be supported by an annular support.
  • the entire plastic structure can rest on a support which, for example, only has corresponding openings for the penetrating joining tool in the area of the joining points.
  • the plastic structure is also punctured at the joint, in particular in the event that the height of the metal edge formed approximately corresponds to or is greater than the thickness of the plastic structure at the joint, i.e. the outer end of the metal edge protrudes beyond the plastic structure, this outer end of the metal edge is bent in the direction of the plastic structure.
  • An undercut is created.
  • the angle of the metal edge to the metal surface in the area around the joint is usually less than 90 ° in such cases.
  • This process can be carried out manually as well as automatically, advantageously in one operation with the piercing process.
  • Appropriately shaped tools e.g. Stamp, hammer or pressing tools, which are brought from the side of the plastic structure to the composite component.
  • an undercut can also be made with a tool in the form of a joining tool, possibly even with the joining tool with which the opening was created, e.g. with a mandrel tapering towards the end.
  • the joining tool is inserted into the previously created opening from the side of the plastic structure and, if necessary, set in a wobble, pendulum or gyroscopic movement. In this way, the metal edge is also pressed against the plastic structure.
  • Undercuts can generally always be created when the diameter of the joining tool is at the level of the surface of the metal component when the maximum penetration or Penetration depth is at least twice the thickness of the composite component at the joint.
  • two or more plastic structures which lie one on top of the other at the joint, are joined together with at least one metal component in one work step by selecting a joining tool diameter with which a metal edge can be produced which also penetrates into the lowest plastic structure or the latter preferably penetrates.
  • the plastic structures lie one above the other at the joint without play, so that a non-positive and positive connection is possible.
  • the joining method according to the invention can also be combined with those from the prior art for the production of composite components.
  • a prior art e.g. Composite component manufactured according to EP-A 0 370 352 are additionally reinforced or stiffened by means of joining points produced with the aid of the method according to the invention.
  • a further metal component is added to a composite component produced according to EP-A 0 370 352 using the method according to the invention.
  • the joining tool i.e. the tool that pierces the metal component at the joint is preferably more stable or stiffer in deformation than the composite of metal component and plastic structure at the joint, in order not only to allow it to be punctured once, but also, in particular, to be suitable for continuous use .
  • Suitable as joining tool materials are e.g. Hardened tool steels or hard metals, such as those used in known punching tools.
  • Various tools can be used for the joining process as long as they ensure that a metal edge is formed when the metal component surface is pierced. Suitable are e.g. Tools and joining machines that are used for sheet metal processing or sheet metal forming.
  • the dimensions of the joining tool can be varied within a wide range, as long as there is a non-positive and positive connection between the metal component and the plastic structure. As a rule, it is advisable to adjust the length and diameter of the joining tool to the thickness of the metal component and plastic structure at the joint, so that in particular no metal parts are chipped off or punched out.
  • Metal edges are preferred, the height of which exceeds the thickness of the plastic structure at the connection point, preferably by 1 to 40, in particular by 5 to 25%.
  • the thickness of the plastic structure is a multiple of the aforementioned diameter of the joining tool, e.g. 4 times or more, on the other hand, permanent and force-fit joining is already achieved without the joining tool completely piercing the plastic structure.
  • a joining tool is advantageously used which tapers towards the piercing end, but which has a cylindrical shape at the maximum penetration depth in the area of the metal edge formed.
  • the cross-sectional areas of the joining tool can in general be arbitrarily shaped, in particular in the area penetrating the composite structure, and can take the form of an ellipse, a circle, triangle, square, rectangle, polygon, star or trapezoid, for example. Any combination of cross-sectional geometries is of course also possible in this area.
  • the joining tool has a circular or almost circular cross section, in particular over the area that penetrates into the composite structure.
  • the joining tool tapers preferentially towards the piercing end. Accordingly, the joining tool can e.g. be designed as a thorn.
  • the joining tool in particular in the area that penetrates the composite structure, is essentially rectilinear with respect to its longitudinal axis, although this of course does not exclude that the said joining tool section can be shaped asymmetrically in the longitudinal section, for example as an asymmetrically shaped one Mandrel.
  • the joining tool tapers advantageously towards the piercing end, either in steps or continuously.
  • the joining tool tapers to a point or almost to a point at the piercing end, for example as with a scriber.
  • the joining tool tapers towards the piercing end much faster than in the previous area.
  • these different segments can be formed by successive, flattening truncated cones. Tools shaped in this way are generally also known as grains.
  • the end of the tool can taper to a point or be completely or partially flattened.
  • the area penetrating into the composite structure has different cross-sectional geometries.
  • the joining tool is cylindrical in the section which is at the level of the metal surface and the adjoining plastic structure after the piercing process has been completed. opposing wall elements of the joining tool are aligned essentially parallel there.
  • the end of the joining tool can be designed as a tapering mandrel and the further areas that also penetrate into the composite structure can have the shape of a thread.
  • the entire joining tool can also have a thread structure. If the joining tool has a thread or thread-like area, it is recommended that the joining tool be rotated into the composite structure, at least as soon as the thread area is at the level of the metal surface at the joint.
  • the joining tool head can have flattened side surfaces that face each other in pairs, e.g. in the shape of a rectangle, square, trapezoid, circle or an ellipse. These side surfaces can be aligned parallel to one another or at an acute angle to one another. The distance between these side surfaces is to be selected so that a wedge shape can be formed which enables penetration into the metal component.
  • This joining head area is usually followed by a cylindrical or cuboid shaped shaft area.
  • the shaft does not taper behind the end of the joining head described above.
  • the joining tool is inserted so deeply into the penetration opening or depression that the area adjoining the head also penetrates into the composite structure. In the event of a penetration opening, an undercut is created in this way in one work step.
  • the joining tool tapers behind the flattened, for example wedge, slot or disk-shaped tool head described above, ie in the region of the tool shaft. Accordingly, the diameter of the joining tool tool head subsequent shaft not beyond the maximum diameter of the head, but is less than this. If the composite structure of metal component and plastic structure is pierced with such a tool to form an opening, the joining tool is preferably inserted so deeply into the opening that it can be rotated. Subsequent movements of the joining tool in opposite directions, in particular with a rotation in the region of approximately 90 °, then immediately lead to the formation of an undercut.
  • the rear brackets of the joining tool head are preferably inclined outwards, that is to say form an obtuse angle with the shank. After rotating through 180 ° or a multiple thereof, for example, the joining tool can then be removed from the feedthrough.
  • the joining tool or the joining tool head can also be designed in the sense of a Phillips screwdriver.
  • a further embodiment comprises the use of a joining tool which has the shape of a screw in its penetration or penetration area, in particular a self-tapping or thread-forming screw, e.g. corresponds to a self-tapping screw.
  • a joining tool which has the shape of a screw in its penetration or penetration area, in particular a self-tapping or thread-forming screw, e.g. corresponds to a self-tapping screw.
  • Such joining tools with a flat flank angle are preferred.
  • Joining tools with a screw-like head or with a thread are preferably rotated into the composite structure and rotated out of the recess or opening in the opposite direction.
  • the joining tool has a hole in the center or is a hollow body, e.g. as a hollow cylinder.
  • the remaining metal edge has a size or shape in relation to the recessed interior space that prevents a metal surface from being punched out when it is pierced through the metal surface.
  • a joining tool can be used which, like a pair of scissors, has a joint and is formed from two or more components and which, when folded, can correspond to one of the previously described joining tools.
  • the joint is particularly advantageously to be attached in such a way that it can be positioned in the region of the depression or the piercing opening, preferably in the lower half of the piercing or the depression, after the metal component and plastic structure have penetrated or pierced. If the components of the joining tool are unfolded in this position, they press the metal edge that may protrude also apart and in this way create an even firmer and stiffer connection, possibly even an undercut in the event of a puncture.
  • the previously described joining process and the joining tool can also be used effectively if the metal edge formed corresponds to the piercing path, ie does not protrude beyond the underside of the plastic structure, or is shorter than the piercing path.
  • joining tools in the form of a curved dome or a claw, which preferably tapers towards the end of the piercing. These do not become straight, but e.g. introduced into the composite structure by means of a rotating or swiveling movement and removed from it again with a corresponding opposite movement. In this way, a joint fastening with a partial undercut is obtained, especially when a recess is formed in the plastic structure.
  • Hybrid components obtained in this way have advantages over their known constructions, with the same weight, in terms of their rigidity or strength and, in particular, also in terms of their simplicity in manufacture.
  • the metal component also called metallic body or metal body
  • a metal component made of non-galvanized or galvanized steel, iron, aluminum, titanium or magnesium is usually used.
  • the metal component can also be coated with a commercially available lacquer layer for reasons of corrosion protection or for optical reasons. Such corrosion protection or paint coatings and their attachment are known to the person skilled in the art.
  • the wall thickness of the metal component at the joint can be varied over a wide range, but is usually set so that the joining tool can easily penetrate the metal wall. It is also advisable to match the thicknesses of the metal component and the plastic structure at the joint.
  • THE APPROPRIATE Suitable metal component thicknesses at the location of the joint are in the range from 0.1 mm to 0.5 cm and preferably in the range from 0.2 to 2 mm.
  • the metal component at the joint in particular in the case of very thick or hard metal components, can also be pre-punched or pre-punched.
  • these holes are many times smaller than the diameter of the joining tool used.
  • the shape of the openings in the metallic body are essentially determined by the cross-sectional shape of the joining tool and can e.g. circular or approximately circular.
  • Common diameters of the openings made in the metallic component are usually in the range from 1 to 50, in particular from 2 to 12 mm.
  • plastic structures Injection-molded or deep-drawn molded parts, including foils and semi-finished products (sheets, tubes, plates, rods, etc.) are suitable as plastic structures.
  • the plastic structures are usually constructed from thermoplastic semi-crystalline or amorphous polymers, but can also be formed from thermosets or mixtures of these polymer classes.
  • thermoplastic polymers are suitable as thermoplastic polymers. Suitable thermoplastic polymers are described, for example, in Kunststoff-Taschenbuch, ed. Saechtling, 25th edition, Hanser-Verlag, Kunststoff, 1992, in particular chap. 4 and references cited therein, and described in the Kunststoff-Handbuch, ed. G. Becker and D. Braun, Volumes 1 - 11, Hanser-Verlag, 1966 - 1996.
  • polyoxy alkylenes such as polyoxymethylene, eg Ultraform ® (BASF AG), polycarbonates (PC), polyesters such as polybutylene terephthalate (PBT), for example Ultradur ® (BASF AG), or polyethylene terephthalate (PET), poly olefins such as polyethylene (PE) or polypropylene (PP), poly (meth) acrylates, e.g. PMMA, polyamides such as polyamide-6 or polyamide-66 (e.g.
  • Ultramid ® 'BASF AG vinyl aromatic (co) polymers such as polystyrene, syndiotactic polystyrene , impact modified polystyrene such as HIPS, or ASA (e.g. Luran ® S; BASF AG), ABS (e.g. Terluran ® ; BASF AG), SAN (e.g.
  • polyarylene ethers such as polyphenylene - ether (PPE), polyphenylene sulfide, polysulfone, polyether sulfone, polyurethane, polylactide, halogen-containing polymer, imide group-containing polymer, cellulose ester, silicone polymer and thermoplastic elastomer.
  • PPE polyphenylene - ether
  • polyphenylene sulfide polysulfone
  • polyether sulfone polyurethane
  • polylactide polylactide
  • halogen-containing polymer imide group-containing polymer
  • imide group-containing polymer cellulose ester
  • silicone polymer thermoplastic elastomer
  • the plastic structures can also contain conventional additives and processing aids.
  • Suitable additives and processing aids are e.g. Lubricants or mold release agents, rubbers, antioxidants, light stabilizers, antistatic agents, flame retardants or fibrous and powdery fillers or reinforcing agents as well as other additives or mixtures thereof.
  • fibrous or powdered fillers and reinforcing materials are carbon or glass fibers in the form of glass fabrics, glass mats or glass silk rovings, cut glass and glass balls.
  • Glass fibers are particularly preferred.
  • the glass fibers used can be made of E, A or C glass and are preferably with a size, e.g. based on epoxy resin, silane, aminosilane or polyurethane and an adhesion promoter based on functionalized silanes. Glass fibers can be incorporated both in the form of short glass fibers and in the form of endless strings (rowings).
  • Suitable particulate fillers are e.g. Carbon black, graphite, amorphous silica, whiskers, aluminum oxide fibers, magnesium carbonate (chalk), powdered quartz, mica, mica, bentonite, talc, feldspar or in particular calcium silicates such as wollastonite and kaolin.
  • plastic structures can also contain colorants or pigments.
  • the aforementioned additives, processing aids and / or colorants are preferably mixed and discharged in an extruder or another mixing device at temperatures of 100 to 320 ° C. while melting the thermoplastic polymer.
  • the use of an extruder is particularly preferred, in particular of a co-rotating, closely intermeshing twin-screw extruder. Processes for producing the plastic molding compositions are well known to the person skilled in the art.
  • Plastic structures including semifinished products of all kinds can be produced from the molding compositions thus obtained, for example by injection molding or deep-drawing. Furthermore, a stiffening ribbing can be molded onto the plastic structure, which is connected to a metallic component to form a hybrid component according to the method according to the invention.
  • the plastic structure has at least one dome-shaped elevation which is open at the top and whose base area can represent a joining surface for interaction with the metal edge formed by the joining tool.
  • a stamp or a support tool can be inserted into the dome-shaped elevations, which at the bottom of the open dome-shaped elevation exerts the counterforce required to form a permanent positive and non-positive connection between the plastic structure and the metal body, if the joining tool first comes from the opposite side is driven through the metal component and then in or through the plastic floor surface of the dome.
  • the plastic structure has two or more dome-shaped elevations which are open at the top, at least two of which are connected to one another by a stiffening plastic rib, the underside of which can also rest on the metal component.
  • the dome-shaped elevations particularly preferably represent intersection points of rib-shaped plastic structures.
  • the open, dome-shaped elevations can also not only be used or sprayed on at the crossing points of a rib stiffening the plastic structure, but also on the stiffening ribs between the crossing points, so that several joints are formed at which the plastic structure and the Metal bodies can be positively and non-positively connected to each other.
  • the plastic structures can of course also be connected to the metal component at further joints in the inventive or conventional manner.
  • the plastic ribs of the ribs stiffening the plastic structure preferably have on their upper edge, that is to say in the area of the highest loads, a wall lying flat and essentially perpendicular to this ribs. On the one hand, this reduces the maximum stresses in the loaded plastic and, on the other hand, prevents the ribbing from buckling or buckling under load.
  • the plastic structure can be designed such that, in addition to the plastic ribs at the upper end of the ribs or domes, it has a closed surface in the manner of a cover which is provided with openings or passages only at the upper ends of the domes. In combination with a U-shaped metal body, this creates a quasi-closed hollow profile.
  • the edge areas of the lid and metal body are also in the inventive or conventional manner, e.g. by means of subsequent injection molding, connected to one another.
  • Composite components in sandwich construction can also be produced in such a way that they consist of a plastic structure arranged in the center or in the core and two associated, preferably flat metal sheets on the outside.
  • the plastic structure serving as a spacer has, for example, the domes described above for the formation of the joints, preferably one part of the domes being open at the top and having a bottom surface on the lower end face and the other part of the domes being formed in exactly the opposite sense , ie is open at the bottom and has a floor surface at the top.
  • the metal sheets can be successively connected to the plastic structure using a joining tool.
  • a tool can be used that has several joining tools on opposite tool sides, with which the sandwich structure is obtained in a positive and non-positive manner in one work step, with stamps being inserted and resting on the opposite side.
  • domes-containing composite components in the case of the above-mentioned domes-containing composite components, they can be produced on the
  • Figures 1.1, 1.2 and 1.3 a metal base body (1), a plastic structure (2) and a joining tool (3) in the area of the connection point before, during and after joining, the joining tool radius being smaller than the thickness of the Composite of metal component and plastic structure at the joint is
  • FIGS. 2.1, 2.2 and 2.3 a metal base body (1), the plastic structure (2) and a joining tool (3) in the area of the connection point before, during and after the joining with a positive and non-positive connection of the metal component and Plastic structure, whereby the joining tool radius is greater than the thickness of the composite of metal component and plastic structure and
  • FIG. 3 composite structure according to FIG. 2.3, in which the protruding metal edge collar has been pressed with a stamp tool (4) in the direction of the underside of the plastic structure,
  • FIGS. 4.1 and 4.2 a metal base body (1) and the plastic structure (2) in the area of the connecting parts after joining with a positive and non-positive connection, the joining tool radius being in the area of the thickness of the composite made of metal component and plastic. Structure lies at the joint and where
  • the metal edge collar is pressed with a stamping tool (4) towards the underside of the plastic structure
  • FIG. 5 shows a composite component made of a round metal body.
  • Figure 6 shows a metal component (1) with a U-shaped
  • Profile created by connecting to a Plastic structure (2) in the form of a base plate becomes a composite component with a closed cross-sectional profile.
  • the plastic plate has ribs (5) for further stabilization.
  • the joining process is carried out both in the overlapping edge areas (6), the floor area in the area of the dome supports (7) and the side walls (8).
  • 1.1 shows a metal component (1) and a plastic structure (2) in the area of the connection point before the joining process.
  • the joining tool (3) is reproduced as part of the overall tool before the actual joining operation. From the representation according to FIGS. 1.1 to 1.3, the wall thickness of the plastic structure between the top and bottom at the joint as well as the maximum radius of the area of the joining tool that penetrates into the composite structure can be seen in more detail.
  • the composite structure rests on two supports (9) and is locked by two supports (10).
  • Figures 2.1 to 2.3 show a metal base body and the plastic structure in the area of the connection point after joining in a positive and non-positive connection.
  • the joining tool has completely penetrated the plastic structure.
  • a metal edge collar protrudes beyond the underside of the plastic structure.
  • the base bearing the plastic structure in the area of the joint shows an opening (11) between the supports (9) into which the joining tool tip can penetrate.
  • FIG. 3 shows a composite component according to FIG. 2.3, in which an undercut has been produced with the aid of a stamping tool (4). Because the metal edge protrudes beyond the underside of the plastic structure, the protruding edge can be bent outwards manually or automatically. The deformed contour tightens or claws the metal edge in the plastic wall, creating a particularly permanent, positive and non-positive connection.
  • Figures 4.1 and 4.2 show a composite component in which the metal edge collar formed corresponds approximately to the thickness of the composite component at the joint.
  • a mandrel-like punch tool (4) With the help of a mandrel-like punch tool (4), the metal edge lying against the plastic structure was widened from the side of the plastic structure underside.
  • a similar result can also be achieved by using the actual joining tool (3) when reaching the maximum penetration depth before pulling out a executes movement, the longitudinal axis of the joining tool roughly describing the shape of a double cone.
  • FIG. 5 shows a composite component with two adjacent joining points, the respective joining tools not being aligned perpendicular to the respective joining surface and the joining directions not running parallel. In this way, a particularly positive and non-positive connection is obtained.
  • FIG. 6 shows a U-shaped metal structure (1) which, together with a plastic base plate (2) having a rib structure (5), forms a composite component.
  • the plastic structure has domes (7), the base plates of which lie against the inside of the metal profile. Joints are provided in the area of the dome floor panels (7), the edge supports (6) and in the area of the metal side walls (8) which are in contact with the rib structure. A particularly rigid and resilient composite structure is obtained.
  • the composite components described can be used in a variety of ways, for example as components or component components in automobile, aircraft or shipbuilding or in the production of furniture, household or electrical appliances.
  • Applications in automobile construction for example Front end modules, front end supports, seat shells, seat structures, instrument panels, door function supports, door function modules, tailgates or side doors.
  • the composite components presented have the advantage over the known hybrid components that the plastic structure can be designed largely free of restrictions since the plastic structure according to the present invention can be manufactured in a separate production step. As a result, the plastic structure according to the invention can be designed to be more load-bearing than those from the prior art. This advantage is expressed in the composite component obtained by higher rigidity or strength with a comparable component weight. Joints can also be created in difficult to access component positions, if necessary manually or semi-automatically, with little effort. If there are several joining points in one component, the joining surfaces can be arranged in any way relative to one another, without making the composite component more difficult or making series production out of the question.
  • Another advantage is that, since there are no additional processing steps, for example gluing steps, short cycle times can be achieved in series production.
  • the white No additional parts or components are required for joining the plastic structure and metal component.
  • the method according to the invention is generally less sensitive to deviations in the positioning of the punched edge and the plastic structure.
  • any plastic structures can be used, regardless of the manufacturing process, whereby fiber-reinforced plastics are equally suitable.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

L'invention concerne un procédé de fabrication d'une pièce composite constituée d'une pièce métallique (1) et d'une structure en plastique (2). Selon ce procédé, la pièce métallique (1) et la structure en plastique (2) sont superposées par liaison de forme sur le point d'assemblage et éventuellement bloquées. Au moins un outil d'assemblage (3), résistant à la déformation, s'enfonce à travers la pièce métallique (1) et à travers ou au moins dans la structure en plastique (2) sur le ou les points d'assemblage. Cet outil se retire ensuite de l'évidement ou de l'orifice formé dans la pièce composite par un mouvement opposé.
PCT/EP2002/007410 2001-07-12 2002-07-04 Procede de fabrication de pieces composites en metal et plastique, pieces composites concernees WO2003006834A1 (fr)

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DE10133292A DE10133292A1 (de) 2001-07-12 2001-07-12 Verfahren zur Herstellung von Verbundbauteilen aus Metall und Kunststoff sowie diese Verbundbauteile
DE10133292.0 2001-07-12

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Cited By (1)

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WO2013185980A1 (fr) * 2012-06-13 2013-12-19 Johnson Controls Gmbh Élément de fixation et procédé de montage correspondant

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GB0310385D0 (en) * 2003-05-07 2003-06-11 Samuel Taylor Ltd Process for joining together components
DE102007028076A1 (de) 2007-06-15 2008-12-18 Innovent E.V. Verfahren zur Herstellung stabiler und mediendichter Metall-Kunststoff-Spritzgussverbunde
DE102008058917A1 (de) 2008-11-25 2010-05-27 Volkswagen Ag Verfahren und Vorrichtung zum Fügen von Werkstücken
DE102009013265B4 (de) 2009-03-11 2013-01-31 Technische Universität Chemnitz Verfahren und Werkzeuge zum Herstellen einer Mischbaugruppe
DE102015206534B4 (de) 2015-04-13 2019-09-19 Volkswagen Aktiengesellschaft Verbindungsanordnung sowie Verfahren zur Herstellung einer solchen Verbindungsanordnung
CN112895474A (zh) * 2019-12-03 2021-06-04 中国商用飞机有限责任公司 一种纤维增强热塑性复合材料与金属的连接方法

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