WO2019214901A1

WO2019214901A1 - Hybrid steel-plastics housing for power electronics

Info

Publication number: WO2019214901A1
Application number: PCT/EP2019/059490
Authority: WO
Inventors: Lothar Patberg; Fabian Schongen; Vanessa Wieschalla
Original assignee: Thyssenkrupp Steel Europe Ag; Thyssenkrupp Ag
Priority date: 2018-05-09
Filing date: 2019-04-12
Publication date: 2019-11-14
Also published as: DE102018207205A1

Abstract

The invention relates to a hybrid component, more particularly a housing or a housing part, in a metal/plastics composite, which has at least one metal sheet shielding electromagnetic irradiation, dynamic or static electrical and/or dynamic or static magnetic fields, and at least one thermoplastic, thermoset or elastomer plastics layer applied by integral bonding and/or interlockingly to the metal sheet, characterised in that the hybrid component has a shielding factor S(ν) of 1.00 to 120.00 dB in the case of a dynamic, magnetic field or a dynamic, electromagnetic field with a frequency v of 0.001 to 1000 kHz, wherein the shielding factor S(ν) is determined from the quotient of the field strength measured at the location of the sink with or without the hybrid component located between sink and source. The present invention further relates to a method for producing the hybrid component and use of same.

Description

Hybrid steel plastic housing for power electronics

Technical area

The invention relates to a hybrid component, in particular a housing or a housing part, in the metal / plastic composite, the at least one electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields shielding metal sheet and at least one on the metal sheet cohesively and / or positively applied thermoplastic , thermosetting or elastomeric plastic layer, characterized in that the hybrid component has a screen factor S (v) of 1.00 to 120.00 dB in a dynamic, magnetic field or a dynamic electromagnetic field with a frequency v of 0.001 to 1000 kHz wherein the screen factor S (v) is determined from the quotient of the field strength measured at the location of the sink with or without hybrid element between sink and source. Furthermore, the present invention relates to a method for producing the hybrid component and its use.

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

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

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

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

WO 2008/008693 A2 discloses a cover plate which contains a metal sheet and a plastic layer and is used to shield electromagnetic radiation. EP 2 597 740 A1 discloses a material for shielding cables through which electrical current flows against electromagnetic radiation. The advantage of this material is that it is flexible and therefore the sheathed cable also remains flexible.

Starting from this prior art, it is an object of the present invention to provide a hybrid component, in particular a housing or a housing part, which in addition to advantageous mechanical properties and good processability, in particular for producing complicated and / or detailed forms, and especially a high Shielding against electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields. Furthermore, according to the invention, a corresponding hybrid component is to be provided which can replace materials known to the person skilled in the art, for example aluminum diecasting.

These objects are achieved according to the invention by a hybrid component in the metal / plastic composite, the at least one electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields shielding metal sheet and at least one on the metal sheet cohesively and / or positively applied thermoplastic, thermosetting or elastomeric Plastic layer, characterized in that the hybrid component has a screen factor S (v) of 1.00 to 120.00 dB in a dynamic magnetic field or a dynamic electromagnetic field with a frequency v of 0.001 to 1000 kHz, wherein the Umbrella factor S (v) is determined from the quotient of the field strength measured at the location of the sink with or without hybrid element situated between the sink and the source.

Furthermore, the objects are transformed by the inventive method for producing a hybrid component, wherein a suitably designed hybrid component in the, preferably three-dimensional shape of the hybrid component, preferably by deep drawing or roll forming, and by the inventive use of the hybrid component as a housing or housing part for at least an electronic component, a battery, a DC / DC converter, an inverter, photovoltaic, circuit boards, power supply equipment, an electrical machine or a part thereof, electrical or electronic equipment, medical equipment, in control cabinets, in server rooms or as server racks, in PC cases, in the aerospace industry, for power electronics or an electronic conductor.

The present in the hybrid component according to the invention, electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields shielding metal sheet may in principle have any known to those skilled composition which causes a high shielding against the above-mentioned radiation or said fields. The metal sheet according to the invention preferably has the following composition (in each case in% by weight)

0.001 to 2, IC, 0.001 to 30.00 Mn,

0.001 to 8.00 Si,

0.01 to 4.00 AI,

0.001 to 1.00 Cr,

Residual Fe and unavoidable impurities, up.

Carbon (C) is present in an amount of 0.001 to 2, 1 wt .-%, preferably 0.001 to 0.800 wt .-%, more preferably 0.002 to 0.700 wt .-%, most preferably 0.002 to 0.650 wt .-%, before ,

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

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

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

Chromium (Cr) is present in an amount of from 0.001 to l, 00 wt .-%, preferably 0.01 to 0.5 wt .-%, particularly preferably 0.01 to 0.4 wt .-%, before.

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

Contains P and Sn.

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

0 to 0.01, preferably 0.001 to 0.004 wt .-% As and / or

0.001 to 0.005 wt .-% B and / or

0.01 to 0.07 wt .-% Cu and / or

0 to 0.3, preferably 0 to 0.01 wt .-% Mo and / or

0.001 to 0.5, preferably 0.001 to 0.3 wt .-% Ti and / or

0 to 0.5, preferably 0.001 to 0.2 wt .-% V and / or 0 to 0.5, preferably 0.001 to 0.2 wt .-% P and / or

0.001 to 0.05 wt .-% S and / or

0.001 to 0.01% by weight of Sn.

Unavoidable impurities in the sense of the present invention are, for example, 0, N, Nb or Sb.

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

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

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

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

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

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

Instead of a metal sheet made of steel material, the hybrid component according to the invention may also have a metal sheet of another metal, for example of magnesium or aluminum. The hybrid component according to the invention, in particular the housing or housing part, has at least one thermoplastic, thermoset or elastomeric plastic layer bonded on the metal sheet in a material-locking and / or form-fitting, in particular materially bonded, manner.

In the context of the present invention, "cohesively" means that the metal sheet and the plastic layer are held together by atomic or molecular forces, so that the two components can only be separated by destruction. "In the context of the present invention," positive locking "means that the metal sheet and the plastic layer in their shapes are adapted to each other so that they hold together, but the two components can be separated without destruction.

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

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

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

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

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

The present invention therefore preferably relates to the hybrid component according to the invention, wherein the at least one thermoplastic plastic is selected from the group consisting of polyolefins, preferably polyethylene (PE), polypropylene (PP), polybutylene (PB) and polyisobutylene (PIB), particularly preferably PE, Polyamides (PA), polycarbonates (PC), thermoplastic polyesters, thermoplastic polyurethanes (PU), polysulfides (PS), polyether ether ketones (PEEK), polyarylene, aromatic polyesters, polyaramides, polyaramid fibers, heterocyclic polymers, liquid crystal polymers (LCP Liquid Crystalline Polymers) , Fluoropolymers, Perfluorooxyalkanes, polyphenylenes, functionalized variants of said polymers and mixtures thereof, preferably a compound having at least two of said polymers, more preferably at least one polyolefin and at least one polyamide.

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

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

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

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

The present invention therefore preferably relates to the hybrid component according to the invention, wherein the at least one elastomeric plastic is selected from the group consisting of natural rubbers (NR), silicone rubbers (SIR), silicone butadiene rubbers (SBR), polyvinyl butyrals (PVB), polyisobutylenes (PIB), isoprene rubbers (IR), ethylene vinyl acetates (EVA), ethylene-propylene-diene rubbers (EPDM), ethylene-propylene copolymers (EPM), ethylene-ethyl acrylate copolymers (E / EA), chloroprene rubbers (CR), butadiene rubbers (BR), acrylonitrile / methyl methacrylates (A / MMA), butyl rubbers (IIR), styrene-butadiene styrenes (SBS), polyether block amides (PEBA), functionalized variants, and mixtures thereof. Applicable for all mentioned polymers which can be used according to the invention is that they can likewise be used as mixtures, compounds and as corresponding polymers which are functionalized by additives. Suitable additives are known to those skilled in the art.

The cohesive application of the at least one thermoplastic, thermosetting or elastomeric plastic layer on the metal sheet can in principle be carried out according to all methods known to the person skilled in the art. Preferably, the application is carried out by continuous or batch processes, wherein steel strips and / or sheets can be processed. Exemplified by his method using a platen press, a laminator, a calender, a double belt press or a belt coater. Accordingly, suitable processes according to the invention are injection molding, thermal pressing, extruding, laminating, calendering or gluing. Such methods are known per se to the person skilled in the art and described in WO 2015/032623 A1.

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

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

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

The at least one metal sheet of the hybrid component according to the invention has, for example, a thickness in the range of 0.1 to 2.5 mm, preferably 0.1 to 1.0 mm, particularly preferably in the range of 0.1 to 0.5 mm. The cohesive applied to the metal sheet thermoplastic, thermosetting or elastomeric plastic layer, however, may rather be slightly thinner. It has, for example, a thickness in the range of 0.01 to 1.2 mm, preferably 0.05 to 1.0 mm, particularly preferably in the range of 0.05 to 0.4 mm.

In experiments carried out by the applicant, it has been found that a hybrid component according to the invention, whose metal sheet and plastic layer have thicknesses in the stated ranges, is well deep-drawable at room temperature in the cupping test according to Erichsen. Serving as a coupling layer thermoplastic, thermosetting or elastomeric plastic layer flows during deep drawing of the hybrid component according to the invention with the metal sheet and does not lose its liability. Due to the present good processability, it is possible that the hybrid component according to the invention can also be present in complicated and / or detailed forms.

Since the hybrid component according to the invention, in particular a housing or a housing part, has good mechanical properties, devices which are located in the interior of the hybrid component can be effectively protected against mechanical influences. Furthermore, it is possible by means of the hybrid component according to the invention to protect devices which are located inside the hybrid component effectively against liquid operating media, dust, soiling. Due to the shielding effect of the hybrid component according to the invention, on the one hand, the interior of the hybrid component can be protected against disturbing electromagnetic fields from the outside. Furthermore, the environment can also be protected by the hybrid component according to the invention from electromagnetic fields that originate from the interior. Further advantages of the hybrid component according to the invention are a weight saving compared to comparable aluminum housings, a higher shielding against aluminum or plastic housings without heating effects, less space compared to plastic housings, improved crash properties and improved rigidity, possibility of functional integration by connection of functional elements to the plastic layer, possibility of mass connection or Surge dissipation.

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

1. Assemble a board or band-shaped hybrid component (cutting);

2. Transport and insert a cut hybrid component into a forming tool with integrated injection molding unit;

3. Uniforms and back molding of the hybrid component blank in one step.

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

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

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

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

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

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

According to a further embodiment of the hybrid component according to the invention, the respective plastic layer serving as a coupling layer is provided with a peelable protective film. The protective film protects the surface of the coupling layer during the transport of the hybrid component and optionally also during the molding of the hybrid component. As a result, prior to the molding of plastic structures, such as plastic ribs, a complex cleaning of the coupling layer surface of contaminants such as oil or grease omitted. In addition, the protective film as a drawing film can improve the sliding properties of the hybrid component in uniforms. The hybrid component according to the invention has a screen factor S (v) of 1.00 to 120.00 dB, preferably 10.00 to 120.00 dB in a dynamic, magnetic field or a dynamic electromagnetic field with at a frequency v of 0.001 to 1000 kHz, preferably 0, 1 to 400 kHz, particularly preferably 0, 1 to 200 kHz, on.

More preferably, the present invention relates to the hybrid component of the invention, wherein screen factor S (v) according to the equation of formula (I)

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

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

The screen factor S (v) is particularly preferably calculated according to the equation of the formula (I)

S (v) = 20 log ^■ (I),

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

Further preferably, the screen attenuation S (v) of the hybrid component according to the invention is determined by a method, comprising at least the following steps:

(A) providing a first coil S1 with a first inductance LI, which is connected to a first signal generator SGI and a device for measuring current I ^ v) to a first circuit,

(B) providing a second coil S2 with a second inductance L2, which is connected to a device for voltage measurement U ₂ (v) to a second circuit, wherein the coils S1 and S2 are spatially arranged to each other so that they are on the same axis of rotation lie and a free space is formed between them, (C) introducing a sample of the hybrid component according to the invention into the free space,

(D) Generation of a sinusoidal voltage with a frequency v of 0.001 to 1000 kHz by the first signal generator SG 1 in the first coil Sl,

(E) measuring the current value li (v) in the first circuit,

(F) measuring the voltage U ₂ (v) in the second circuit,

(G) Determining the screen factor S (v) via the equation of the formula (I)

S (v) = 20 log (I),

where lio (v) is the current in the first circuit and U ₂₀ (v) is the voltage in the second circuit, each without a sample inserted.

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

The hybrid component according to the invention can in principle take any form that can be imagined by the person skilled in the art. In a preferred embodiment, the hybrid component according to the invention is a housing or a housing part. Examples of housing parts are according to the invention covers, covers, trays, flaps, frames, compartments, brackets, cabinet carcasses, partitions or partitions.

The inventively preferred housing or housing parts are in particular those for at least one electronic component, a battery, a DC / DC converter, an inverter, photovoltaic, circuit boards, devices for the power supply, an electrical machine or a part thereof, electrical or electronic equipment, medical Devices, in control cabinets, in server rooms or as server racks, in PC enclosures, in the aerospace industry, for power electronics or an electronic conductor.

The present invention also relates to a method for producing a hybrid component according to the invention, wherein a suitably designed, at least predominantly, flat hybrid component is formed into the, preferably three-dimensional, shape of the hybrid component, preferably by deep drawing, roll forming or bending.

The present invention also relates to a method for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, wherein a hybrid component according to the invention is used, wherein the plastic layer formed as a coupling layer by injection molding, compression molding, extrusion or thermal pressing a three-dimensional plastic structural body is integrally formed materially.

As already stated, the hybrid component according to the invention enables the production of a three-dimensional molded hybrid component of metal and plastic with a structural body, preferably rib body, made of plastic without application of adhesive. This significantly simplifies the production of the hybrid component.

According to a preferred embodiment of the method according to the invention, the hybrid component is formed into a three-dimensional shape before molding of the structural body. The uniforms is preferably carried out by deep drawing or roll forming.

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

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

Another variant of the method according to the invention is that the at least predominantly flat hybrid component is formed by roll forming, wherein during or after the forming of the hybrid component, a rotatable, wheel-shaped tool is used to press the structural body, and the tool with a profile having at least one cavity is provided for pressing and three-dimensional shapes of a plastic mass. With this embodiment of the method can be produced in particular as a profile carrier designed hybrid components of the type mentioned in mass production effectively.

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

The present invention also relates to the method for shielding electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields, wherein source and / or sink are at least partially surrounded by a hybrid component according to the invention, in particular a housing or housing part.

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

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

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

The hybrid component according to the invention can advantageously as a housing or housing part for at least one electronic component, a battery, a DC / DC converter, an inverter, photovoltaic, circuit boards, devices for the power supply, an electrical machine or a part thereof, electrical or electronic equipment, medical Devices, in control cabinets, in server rooms or as server racks, in PC enclosures, in the aerospace industry, for power electronics or an electronic conductor.

The present invention therefore furthermore relates to the use of the hybrid component according to the invention as a housing or housing part for at least one electronic component, a battery, a DC / DC converter, an inverter, photovoltaics, printed circuit boards, devices for the power supply, an electrical machine or a part thereof , electrical or electronic equipment, medical equipment, in control cabinets, in server rooms or as server racks, in PC cases, in the aerospace industry, for power electronics or an electronic conductor.

The present invention also relates to a housing or housing part for at least one electronic component, a battery, a DC / DC converter, an inverter, photovoltaics, circuit boards, devices for the power supply, an electrical machine or a part thereof, electrical or electronic systems, medical Devices, in cabinets, in server rooms or as server racks, in PC cases, in the aerospace industry, for power electronics or an electronic conductor, comprising at least one inventive hybrid component.

It is according to the invention possible that only a part of the housing, such as a lid or bottom, consists of the material according to the invention or contains this and another part of the housing of another material, such as plastic, metal and / or ceramic is or contains. In the hybrid component according to the invention, the metal side can be used either inside or outside.

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

characters

The reference symbols used in FIGS. 1, 2 and 3 have the following meanings:

1 sheet metal

2 plastic layer

3 plastic structural body

4 lids

5 floor

FIG. 1 shows a hybrid component according to the invention in the metal / plastic composite, which has an electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields shielding metal sheet and a cohesively and / or positively applied thermoplastic, thermoset or elastomeric plastic layer on the metal sheet, wherein the metal is on the outside and the plastic layer on the inside. Plastic structure bodies are applied to the plastic layer.

FIG. 2 shows a hybrid component according to the invention in the metal / plastic composite, which has an electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields shielding metal sheet and a cohesively and / or positively applied thermoplastic, thermoset or elastomeric plastic layer on the metal sheet, wherein the metal on the inside and the plastic layer are on the outside. Plastic structure bodies are applied to the plastic layer.

FIG. 3 shows a hybrid component according to the invention in the metal / plastic composite. In this case, the lid and bottom are designed as the hybrid components according to Figures 1 or 2. Furthermore, there is a frame of metal (1) outside and plastic layer (2) and plastic structural body (3) inside.

example

An electrolytically galvanized metal sheet of DP1000 grade 1 mm thick is coated with a film of polyamide-polyethylene compound having a thickness of 50 μm. The material thus obtained is then formed by deep drawing into a hybrid component. At this component, the shield is determined at different frequencies. The values obtained are shown in Table 1.

Table 1: Shielding S at Different Frequencies †

Industrial Applicability

The hybrid components according to the invention combine good mechanical characteristics and high shielding against electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields, so that advantageous three-dimensionally shaped hybrid components can be produced as housing or housing parts.

Claims

claims

1. Hybrid component in the metal / plastic composite, which has at least one electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields shielding metal sheet and at least one on the metal sheet materially and / or positively applied thermoplastic, thermosetting or elastomeric plastic layer, characterized the hybrid component has a screen factor S (v) of 1.00 to 120.00 dB for a dynamic magnetic field or a dynamic electromagnetic field with a frequency v of 0.001 to 1000 kHz, the screen factor S (v) being off the quotient of the field strength measured at the location of the sink with or without located between sink and source hybrid component is determined.

2. Hybrid component according to claim 1, characterized in that it is a housing or a housing part.

3. hybrid component according to claim 1 or 2, characterized in that the thermoplastic, thermosetting or elastomeric plastic layer on the entire metal sheet or only on a part of the metal sheet materially and / or positively, in particular cohesively, is applied

4. hybrid component according to one of claims 1 to 3, characterized in that the metal sheet has the following composition (each in wt .-%)

- 0.001 to 2.1 C,

0.001 to 30.00 Mn,

0.001 to 8.00 Si,

- 0.01 to 4.00 AI,

0.001 to 1.00 Cr,

Residual Fe and unavoidable impurities.

5. hybrid component according to one of claims 1 to 4, characterized in that the screening factor S (v) of the hybrid component by detecting the voltage U2 (v) in a second coil, which is induced by a current ll (v) in a first coil while a sample of the hybrid component is between the first and second coils and the coils are at a distance of at most 40 mm, is determined.

6. Hybrid component according to one of claims 2 to 5, characterized in that the thermoplastic, thermosetting or elastomeric plastic layer is located on the inside and / or on the outside of the housing or the part of the housing.

7. Hybrid component according to one of claims 1 to 6, characterized in that the plastic layer is formed as a coupling layer for cohesive, adhesive-free connection of at least one made of plastic or manufactured structural body.

8. hybrid component according to one of claims 1 to 7, characterized in that the side of the metal sheet on which the plastic layer is applied, preferably at the points where the plastic layer is present, a the adhesion of the plastic layer improving surface.

9. hybrid component according to one of claims 1 to 8, characterized in that the screen factor S (v) according to the equation of formula (I)

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

10. Hybrid component according to one of claims 1 to 9, characterized in that the metal sheet containing a microstructure containing 0 to 100 wt .-% of ferrite, 0 to 95 wt .-% bainite, 0 to 20 wt .-% pearlite, 0 to 100 Wt .-% martensite or up to 100 wt .-% martensite, 0 to 20 wt .-% retained austenite and optionally carbides, wherein the sum results in each case 100 wt .-%, comprising.

11. Hybrid component according to one of claims 1 to 10, characterized in that the at least one thermoplastic material is selected from the group consisting of polyolefins, polyamides (PA), polycarbonates (PC), thermoplastic polyesters, thermoplastic polyurethanes (PU), polysulfides ( PS), polyether ether ketones (PEEK), polyarylene, aromatic polyesters, polyaramides, polyaramid fibers, heterocyclic polymers, liquid crystal polymers (LCP Liquid Crystalline Polymers), fluoropolymers, perfluorooxyalkanes, polyphenylenes, functionalized variants of said polymers and mixtures thereof.

Hybrid component according to one of claims 1 to 10, characterized in that the at least one thermosetting plastic is selected from the group consisting of epoxy resins (EP), urea-formaldehyde resins (UF), phenol-formaldehyde resins (PF), melamine-formaldehyde resins (MF) . Melamine / phenol formaldehydes (MPF), thermosetting polyesters (PES), polyurethanes (PUR), unsaturated polyesters (UP), partially crosslinked (bi-stage) thermosetting polymers, functionalized variants of the polymers mentioned and mixtures thereof.

13. Hybrid component according to one of claims 1 to 10, characterized in that the at least one elastomeric plastic is selected from the group consisting of natural rubbers (NR), silicone rubbers (SIR), silicone butadiene rubbers (SBR), polyvinyl butyrals ( PVB), polyisobutylenes (PIB), isoprene rubbers (IR), ethylene vinyl acetates (EVA), ethylene-propylene-diene rubbers (EPDM), ethylene-propylene copolymers (EPM), ethylene-ethyl acrylate copolymers (E / EA) , Chloroprene rubbers (CR), butadiene rubbers (BR), acrylonitrile / methyl methacrylates (A / MMA), butyl rubbers (IIR), styrene-butadiene styrenes (SBS), polyether block amides (PEBA), functionalized variants and Mixtures thereof.

14. A method for producing a hybrid component according to one of claims 1 to 13, characterized in that a suitably designed hybrid component in the, preferably three-dimensional shape of the hybrid component is formed, preferably by deep drawing or roll forming.

15. A method for shielding electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields, characterized in that the source and / or sink at least partially surrounded by a hybrid component, in particular a housing or housing part according to one of claims 1 to 13 become.

16. Use of the hybrid component according to one of claims 1 to 13 for the shielding of electromagnetic radiation, dynamic or static electrical and / or dynamic or static magnetic fields.

17. Use of the hybrid component according to one of claims 1 to 13 as a housing or housing part for at least one electronic component, a battery, a DC / DC converter, an inverter, photovoltaic, printed circuit boards, devices for the power supply, an electrical machine or a part thereof , electrical or electronic equipment, medical devices, in control cabinets, in server rooms or as server racks, in PC enclosures, in the aerospace industry, for power electronics or an electronic conductor.

IS. Housing or housing part for at least one electronic component, a battery, a DC / DC converter, an inverter, photovoltaic, circuit boards, power supply devices, an electrical machine or a part thereof, electrical or electronic equipment, medical devices, in control cabinets, in Server rooms or as server racks, in PC cases, in aerospace engineering, for a power electronics or an electronic conductor, comprising at least one hybrid component according to one of claims 1 to 13.