DE10133292A1 - Composite metal and plastic product manufacture involves penetration of a tool through the metal and plastic parts to form a positive connection between them - Google Patents

Abstract

The metal (1) and plastic (2) parts of the component are placed in contact with each other and may be held (10) together. A tool (3) for joining both parts is driven through the metal part and either completely or partly through the plastic part. The tool is then retracted leaving a recess or opening in the composite component in which the deformed metal part makes a positive connection. The plastic part is heated above room temperature in the joining area and the joining tool is moved perpendicularly onto the metal surface. Alternatively two non-parallel joining tools may be used. The joining tool is rotated around its own axis, in particular when retracting from the maximum penetration point. The tool may also perform an oscillating, wobbling or spinning movement. The maximum joining tool diameter which penetrates the composite component is twice the thickness of the latter. After removal of the joining tool from the opening an undercut may be formed in the metal using a hammer, punch or further joining tool. Joining tools comprise a tapering mandrel which may have an asymmetric shape. The penetration area of the tool may be shaped either like that of a self-cutting or thread forming screw or a slotted or crossed slot screw driver. An Independent claim is included for a composite part produced by the process.

Description

The invention relates to a method for producing a Composite component made of a metal component and one Plastic structure, these composite components and their use as components or Component components in automotive, aircraft or shipbuilding or in the manufacture of furniture, household or electrical appliances.

Composite molded parts made of metal and plastic are known to the person skilled in the art known and u. a. as so-called hybrid components in Automotive engineering, e.g. B. in the form of front-end modules. By combining the materials metal and plastic products with low weight, great rigidity and Manufacture high resilience inexpensively. The Plastic molded part can also be used to get one additional functions such as Hinge parts, bearings, cable clamps or snap and Integrate screw connections into the component.

A method for producing such composite molded parts is known, for. B. in the published patent application EP-A 0 370 352, according to which a thin sheet of metal with openings in one shell-shaped injection mold inserted and the melt-shaped plastic is injected accordingly. This process is very complex and prone to wear. It requires a high level of commitment in terms of on tool maintenance. A high proportion of rejects often cannot be avoided. You also need for everyone new model variant or change a new one, mostly complicated injection mold. Series production is therefore often included imponderable risks.

In the as yet unpublished European patent application with the file number 00119476.0 will be further Metal / plastic joining techniques described. These are said to be less Share in product committee. For example, that partial or full surface bonding of metal and plastic in the contact areas, the subsequent formation of Plastic rivets by melting in the openings of the Sheet metal, connecting with screws or snap hooks, and that Join by flanging flaps on the metal sheet or on the edges or openings of the plastic structure disclosed. However, these joining techniques make either use other materials, e.g. B. adhesives or screws, or additional procedural steps required.

With an increasing demand for highly integrated lightweight components It would be desirable not only in the automotive industry to be able to use a practicable connection technology that can be handled flexibly, complicated Composite component geometries allows and easily for series production suitable.

It was therefore the task of a simple and inexpensive Joining process for the production of composite components made of metal and to provide plastic that can be used especially very complex component geometries in a simple manner can be realized on an industrial scale or in small series.

Accordingly, a method for manufacturing a Composite component made of at least one metal component and at least one Plastic structure found, in which the metal component and the plastic structure at the point to be joined with a positive fit put on or on top of each other, if necessary locked, at least a deformation-resistant joining tool at the joint or joints through the metal component and through or at least in the Plastic structure drives and this through an opposite movement again from the depression or opening of the Composite component removed.

Furthermore, those produced by this process were Composite components and their use as components or Component components in automotive, aircraft or shipbuilding or at Manufacture of furniture, household or electrical appliances found.

In the method according to the invention there are metal components and Plastic structure before joining at least in the area of Joining point on or on top of each other. Not yet assembled composite of metal component and plastic structure preferably during the joining process, for example with the help a tool, locked, so that these component components do not move against each other when joining. For locking purposes methods and tools known to those skilled in the art, for example presses, clamps, clips or collets, be used. Metal component and plastic structure can be used partially or completely glued together his.

The joining process is done in such a way that a Deformation-stable or rigid joining tool at the joint by the adjacent surface of the metal component in or, depending on Thickness of the plastic structure at the joint or the length of the Joining tool is driven through this plastic structure. A positive and non-positive connection comes from the inventive method in that the Metal surface is broken open by the joining tool and the forming metal edge usually in the immediately adjacent Plastic structure penetrates, the walls of the Joining tool the metal edge that forms on the plastic structure press it. The joining tool also penetrates the plastic structure shows the composite structure at the joint regularly Opening on.

In a preferred embodiment, the plastic structure at least in the area of the joint above room temperature, d. H. temperature above about 25 ° C. Depending on Plastic material can also be chosen at temperatures that just below the melt temperature of the underlying Plastic material lie. Of course, the entire plastic structure or the composite of metal component and Plastic structure have such an elevated temperature. to Heating of the plastic structure and / or metal component can occur common procedures and heaters can be used. Local or localized heating is possible, e.g. B. means Laser radiation or ultrasound. With the invention proposed methods can accordingly both conventional Plastic structures, i.e. those that have ambient temperature, as well as freshly injected tool-falling parts that increase Have temperature and therefore usually still relatively soft are, but also post-tempered plastic structures, d. H. those that were raised to a level just before joining Have been brought to a shape and temperature non-positive connection with a metal component.

Furthermore, the joining tool can have a temperature above room temperature.

Via a relative movement of the joining tool and the composite component the former can be removed from the joint again, whereby one additionally to support the opposite movement can also operate a scraper. For example, if Joining tool withdrawn from the recess formed, can a conveniently positioned in the area of the joint Scraper help that the composite component and that, if necessary jammed joining tool can be separated again.

The scraper can e.g. B. also in the form of a cylinder or in any other geometry complete the joining tool or partially surrounded, the joining tool in the Scraper can move up and down.

The joining process can be manual, semi-automatic or be carried out fully automatically. Multiple joining tools can at different times or simultaneously Joints are driven into the composite structure. One or Several joining tools can also be part of one Be machine tool with which the joining tools in any arrangement or different time sequences can be used.

The joining tool is suitably driven vertically or almost perpendicular to the joint surface in the composite structure.

Two or more joining tools can also be parallel or almost parallel to the joining process to produce a Composite component to be aligned. At least two are preferred Joining tools during the joining process in relation to a plane Metal component surface not aligned parallel to each other.

The penetration or penetration process of the joining tool and / or the The process of separating the joining tool and the composite component can by rotating the joining tool about its longitudinal axis be overlaid. The rotary movements advantageously run when penetrating or penetrating and separating when the joining tool has a thread structure, in opposite directions.

Another embodiment of the method according to the invention includes a wobble, pendulum or gyroscopic movement of the Joining tool when penetrating or penetrating the composite structure, especially when or after reaching the maximum penetration or penetration depth, i.e. when ingested or during opposite movement. Basically these are Joining tool movements, in which the longitudinal axis of the joining tool from its original joining direction is brought. This wobble, pendulum or gyro motion can also be removed when the Joining tool from the recess or the opening in the composite component to be kept. With the wobble, pendulum or gyroscopic movement the longitudinal axis of the joining tool, for example, the shape a cylinder, a single or double cone or two describe triangles standing on top of each other. The aforementioned wobble, pendulum or gyroscopic movements of the joining tool are suitable in one operation, d. H. together with the Joining process to create an undercut.

In a preferred embodiment, especially if the Plastic structure is pierced or if the Plastic structure itself due to construction or material can perform a supporting function are in the area of Joining point or around it on the side of the Plastic structure one or more support points, also underlay or Carrier stamp called for the composite component. For example, the The joint is supported by an annular support. Of Furthermore, the entire plastic structure can be placed on one pad rest, for example, only in the area of the joints corresponding omissions for the penetrating joining tool having.

If the plastic structure at the joint is also pierced, can in particular in the event that the amount of education Metal edge of the thickness of the plastic structure at the joint is approximately the same or larger, d. H. the outer end of the Metal edge protrudes beyond the plastic structure, this outer end of the metal edge towards the pending Plastic structure can be bent. A so-called arises Undercut. The angle of the metal edge to the metal surface in the In such cases, the area around the joint is usually less than 90 °. This process can be manual as well as automated, conveniently in one operation with the piercing process, be made. To create such undercuts, you resort preferably on appropriately shaped tools, e.g. B. stamp, Hammer or crimping tools back from the side of the Plastic structure can be introduced to the composite component. Furthermore an undercut can also be made with a tool in the form of a Joining tool, possibly even with the joining tool, with the the opening has been made, e.g. B. with a End tapering thorn to be brought about. This will be Joining tool from the side of the plastic structure to the front created opening and optionally in a wobble, Pendulum or gyroscopic movement offset. In this way the Metal edge also pressed against the plastic structure.

Undercuts can generally always be created if the diameter of the joining tool is at the height of the Surface of the metal component when the maximum penetration or penetration depth at least twice the thickness of the Composite component at the joint.

Undercuts are used to achieve rigidity and stability to increase the composite components according to the invention again.

In another embodiment, two or more Plastic structures that lie on top of each other at the joint, in one operation with at least one metal component assembled by choosing a joining tool diameter with which a Metal edge can be created, which is also in the bottom Plastic structure penetrates or preferably penetrates them. For this purpose, the plastic structures are located at the joint without play on top of each other, so that a non-positive and positive Connection becomes possible.

Of course, the joining method according to the invention can also with those from the prior art for the production of Composite components can be combined. For example, one after the State of the art, e.g. B. manufactured according to EP-A 0 370 352 Composite component in addition with the help of the invention Process generated joining points are reinforced or stiffened. Or on a composite component produced in accordance with EP-A 0 370 352 becomes a further metal component according to the inventive method added.

The joining tool, i. H. the tool that attaches the metal component to the Punctures joint, is preferably more stable or deformation - stiffer than the composite of metal component and plastic structure at the joint, in order not to just push through once enable, but in particular for continuous use in Question to come. Suitable as joining tool materials are e.g. B. hardened tool steels or hard metals, such as those are used in known punching tools.

For the joining process, joining tools can be used in many different ways Form are used as long as they ensure that the Piercing the metal component surface forms a metal edge becomes. Are suitable for. B. tools and joining machines for Sheet metal processing or sheet metal forming can be used.

The dimensions of the joining tool can vary widely can be varied as long as a positive and positive connection between the metal component and the plastic structure. In As a rule, it is recommended to measure the length and diameter of the Joining tool to the thickness of the metal component and plastic structure the joint, so that in particular no metal parts knocked off or punched out.

Is the largest diameter of the joining tool section that penetrates into the composite structure or which is reached when the maximum depth of penetration or penetration at the level of Surface of the upcoming metal component is approximately the same that or greater than twice the total thickness of Metal component and plastic structure at the joint, it is advantageous to completely pierce the plastic structure and not just penetrate this with the joining tool to the To enable formation of an undercut.

Metal edges are preferred, the height of which is the thickness of the Plastic structure at the connection point, preferably by 1 to 40%, especially 5 to 25%.

Especially when the thickness of the plastic structure compared to the aforementioned diameter of the joining tool a multiple is, e.g. B. 4 times or more, on the other hand, becomes permanent and non-positive joining has already been achieved without this Joining tool completely pierces the plastic structure. In this case a joining tool is advantageously used, the tapered towards the piercing end, but at maximum Penetration depth in the area of the metal edge formed Has cylindrical shape.

The cross-sectional areas of the joining tool can be in particular in the area penetrating the composite structure in general be arbitrarily shaped and for example the shape of an ellipse, of a circle, triangle, square, rectangle, polygon, star or accept trapezes. Of course in this area Any combination of cross-sectional geometries is also possible. In one embodiment, the joining tool has, in particular, over the area that penetrates the composite structure circular or almost circular cross section. The joining tool preferentially tapers towards the piercing end. Accordingly, it can Joining tool e.g. B. be designed as a mandrel.

The joining tool is particularly advantageous in the Area that penetrates the composite structure in relation to its Longitudinal axis formed substantially straight, this of course, does not exclude that the named Joining tool section can be asymmetrically shaped in longitudinal section, for example as an asymmetrically shaped mandrel. The Joining tool advantageously tapers towards the piercing end, either in stages or continuously. In one embodiment, running the joining tool is pointed or almost pointed at the piercing end, z. B. like a scriber. In another embodiment The joining tool tapers significantly towards the piercing end faster than in the previous area. For example, you can these different segments by successive, flattened truncated cones are formed. So shaped Tools are also commonly known as grains. The Joining tool can in the above-described embodiments tapered or flattened in whole or in part available.

In a further embodiment, the in Composite structure penetrating area different cross-sectional geometries on. For example, in a preferred embodiment Joining tool in the section that changes after completion Puncture process at the level of the metal surface and the adjacent one Plastic structure is cylindrical, d. H. yourself Opposing wall elements of the joining tool are there in the aligned essentially parallel.

Furthermore, the end of the joining tool can be a pointed mandrel be designed and the other, also in the Areas penetrating composite structure have the shape of a thread. Of course, the entire joining tool can also be one Have thread structure. The joining tool has one Thread or thread-like area, it is recommended that Joining tool, at least as soon as the thread area is on the Height of the metal surface at the joint, rotating in the composite structure.

Another embodiment includes a joining tool that is in its front penetration or puncture area is wedge-shaped is formed, for example in the form of a Slot screwdriver. In this case, the joining tool head can be in pairs opposing flattened side surfaces z. B. in the form of a Rectangle, square, trapezoid, circle or an ellipse exhibit. These side surfaces can be parallel to each other be aligned or at an acute angle to each other. The The distance between these side surfaces should be chosen so that a Wedge shape can be formed, which penetration into the Metal component allows. This joining head area closes usually a cylindrical or cuboid Shaft area. In one embodiment, the Do not shank behind the end of the joining head described above. In in this case, the joining tool is inserted so deeply into the Piercing hole or depression that also applies to the head subsequent area penetrates into the composite structure. In the case A through opening is already created in this way Work an undercut.

In a further embodiment, the joining tool tapers behind the flattened, e.g. B. wedge, slit or disk shaped tool head, d. H. in the area of Tool shank. Accordingly, the diameter of the protrudes Joining tool head of the following shank does not exceed the maximum Diameter of the head, but is less than this. Becomes the composite structure of metal component and plastic structure with such a tool with the formation of an opening puncture, the joining tool is preferably inserted as deep into the Opening one that it can be rotated. Subsequent opposite Movements of the joining tool, especially when rotating The area around 90 ° then leads directly to the formation of a Undercut. The rear bracket of the Joining tool head inclined outwards, so form a blunt Angle with the shaft. After rotation by z. B. 180 ° or a The joining tool can then carry out many of these again from the feedthrough be removed.

In the same way as for one using a screwdriver-like joining tool, the joining tool or the joining tool head also in the sense of a Phillips screwdriver.

Another embodiment includes the use of a Joining tool that in its penetration or penetration area of the mold a screw, especially a self-tapping or thread-forming screw, e.g. B. corresponds to a self-tapping screw. Such joining tools with a flat one are preferred Flank angle. Joining tools with a screw-like head or with a thread are preferably rotating in the composite structure rotating in one or the opposite direction out of the recess or Opening led out.

In a further embodiment, the joining tool has a center a hole on or is as a hollow body, for. B. as a hollow cylinder, educated. The remaining metal edge, however, has Size or shape in relation to the recessed interior to have a puncture through the metal surface Punching out a metal surface prevented.

Furthermore, a joining tool can be used, which is the same as for a pair of scissors has one joint and two or more Components is formed and that in the collapsed state can correspond to one of the previously described joining tools. The joint is particularly advantageous with this joining tool to be attached in such a way that after penetration or penetration of Metal component and plastic structure in the area of the recess or the piercing opening, preferably in the lower half of the Penetration or the recess can be positioned. folds the components of the joining tool in this position apart, press the metal edge that may protrude also apart and create one more in this way firmer and stiffer connection, if necessary in the event of a puncture even an undercut. Of course, you can go ahead described joining process as well as the joining tool be used effectively when the metal edge formed Puncture path corresponds to d. H. not over the bottom of the Plastic structure protrudes, or is shorter than that Durchstoßweg.

Alternatively, joining tools in the form of a curved mandrel or a claw, which is preferably the Pushing through tapered, can be resorted to. These will not straightforward, but z. B. by means of a rotary or pivoting movement introduced into the composite structure and with a corresponding opposite movement again removed from this. To this In particular, this is obtained even when one is being trained Deepening in the plastic structure with a fastening a partial undercut.

Hybrid components obtained in this way face each other corresponding known constructions with the same weight advantages with regard to their rigidity or strength and in particular also for ease of manufacture.

The metal component, also metallic body or metal body called, can be made of any metal or alloy, if this is in the solid state after penetration with a Joining tool provides a metal edge that is hard enough to use with the Plastic structure a positive and positive connection to be able to enter. A metal component is usually made non-galvanized or galvanized steel, iron, aluminum, titanium or Magnesium used. The metal component can for the sake of Corrosion protection or for optical reasons also with a commercially available lacquer layer. Such corrosion protection or paint coatings and their application are the specialist known.

It has to have a strength under the joining conditions that the metal edges created at the breakthrough with a sufficient strength and rigidity. The wall thickness of the Metal component at the joint can be used in wide areas are varied, but is usually set so that the joining tool can easily penetrate the metal wall. It is also recommended that the thickness of the metal component and Matching the plastic structure at the joint. Suitable metal component thicknesses at the location of the joint are in the area from 0.1 mm to 0.5 cm and preferably in the range from 0.2 to 2 mm.

Instead of continuous, uniform metal surfaces, this can be done Metal component at the joint, especially for very thick ones or hard metal components, also pre-punched or be pre-cut. However, these holes are many times smaller than the diameter of the joining tool used.

The shape of the openings in the metallic body are in the essentially determined by the cross-sectional shape of the joining tool and can e.g. B. circular or approximately circular.

Common diameters of those produced in the metallic component Breakthroughs are usually in the range from 1 to 50, in particular from 2 to 12 mm.

Injection molded or thermoformed come as plastic structures Molded parts, including foils and semi-finished products (sheets, tubes, Plates, rods, etc.) in question. The plastic structures are usually from thermoplastic semi-crystalline or amorphous polymers, but can also be made of thermosets or Mixtures of these polymer classes are formed.

All known to those skilled in the art come as thermoplastic polymers Thermoplastics into consideration. Suitable thermoplastic polymers are for example in the plastic paperback, ed. Saechtling, 25th edition, Hanser-Verlag, Munich, 1992, in particular Cape. 4 and references cited therein, and in the plastics manual, Edited by G. Becker and D. Braun, volumes 1-11, Hanser-Verlag, 1966-1996.

Examples are suitable thermoplastics Polyoxyalkylenes such as polyoxymethylene, e.g. B. Ultraform® (BASF AG), Polycarbonates (PC), polyesters such as polybutylene terephthalate (PBT), e.g. B. Ultradur® (BASF AG), or polyethylene terephthalate (PET), Polyolefins such as polyethylene (PE) or polypropylene (PP), Poly (meth) acrylates, e.g. B. 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. Luran®; BASF AG) or AES polymers, polyarylene ethers such as Polyphenylene ether (PPE), polyphenylene sulfide, polysulfone, polyether sulfone, Polyurethanes, polylactides, halogen-containing polymers, Polymers containing imide groups, cellulose esters, silicone polymers and Thermoplastic elastomers. Mixtures can also be used different thermoplastics as materials for the plastic structures be used. These mixtures can be or multi-phase polymer blends.

The plastic structures can also be customary Contain additives and processing aids.

Suitable additives and processing aids are e.g. B. 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.

As examples of fibrous or powdery filling and Reinforcing materials are carbon or glass fibers in the form of Glass fabrics, glass mats or glass silk rovings, cut glass as well Called glass balls. Glass fibers are particularly preferred. The Glass fibers used can be and are made of E, A or C glass preferably with a size, e.g. B. on epoxy resin, silane, Aminosilane or polyurethane base and an adhesion promoter the basis of functionalized silanes. The training The glass fibers can be in the form of short glass fibers as well Form of endless strings (rowings).

As particulate fillers such. B. 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.

Furthermore, the plastic structures can also contain colorants or Pigments included.

The aforementioned additives are preferred, Processing aids and / or colorants in an extruder or other mixing device at temperatures from 100 to 320 ° C below Melting of the thermoplastic polymer mixed and discharged. The use of an extruder is particularly preferred in particular a co-rotating, tightly meshing Twin-screw extruder. Process for the preparation of the Plastic molding compositions are well known to the person skilled in the art.

Plastic structures can be made from the molding compositions thus obtained Manufacture (also semi-finished products) of all kinds, e.g. B. after injection molding or deep drawing process.

On the plastic structure, which with a metallic component to a hybrid component according to the inventive method stiffening ribbing can also be connected be injected or be.

In a further embodiment, the plastic structure at least one dome-shaped upward open survey, the Base area a joint surface for interaction with the through the joining tool can represent formed metal edge.

A stamp can be placed in the dome-shaped elevations which are open at the top or a support tool are introduced, which at the bottom of the open dome-shaped elevation to form a permanent positive and non-positive connection between the plastic structure and metal body applies required drag if that Joining tool from the opposite side first through the Metal component and then in or through the plastic floor surface of the cathedral.

In a preferred embodiment, the Plastic structure over two or more dome-shaped, open at the top Elevations, at least two of which are stiffened Plastic rib, the underside of which can also rest on the metal component, are interconnected. The are particularly preferred Dome-shaped elevations crossing points more rib-shaped Plastic structures. These plastic structures can be without manufacture further using common injection molding processes. Special Strength and stiffness are used in composite components achieved when that or the metal components with each or almost each base plate of a dome-shaped elevation by means of a Joining tool piercing are connected.

The open, dome-shaped surveys can also be used not just in the intersection of a plastic structure use stiffening ribbing or spray, but also on the stiffening ribs between the crossing points so that several joints are formed, at which the Plastic structure and the metal body with each other can be non-positively connected. In addition to the cathedral surfaces, the Plastic structures of course also on others Joining points with the metal component according to the invention or be connected in a conventional manner.

The plastic ribs that stiffen the plastic structure Ribs preferably have on their upper edge, i. H. by doing Range of the highest loads, one essentially perpendicular to this ribbing arranged, lying flat wall.

On the one hand, this reduces the maximum stresses in the loaded Plastic and on the other hand prevents buckling or buckling the ribbing under load.

Furthermore, the plastic structure can be designed that they are next to the plastic ribs at the top of the ribs or dome a closed surface in the manner of a lid which only has openings at the upper ends of the domes or Culverts is provided. In combination with a U-shaped This creates a quasi-closed metal body Hollow profile. In one embodiment, the edge areas are also of lid and metal body on or according to the invention conventional way, e.g. B. by means of subsequent extrusion molding, connected with each other.

Composite components can also be manufactured in sandwich construction such that they are arranged in the middle or in the core Plastic structure and two connected, external, preferably flat metal sheets exist. As Spacer serving plastic structure indicates training the joints, for example, the domes described above on, preferably one part of the domes open at the top is and has a bottom surface on the lower end face and the other part of the dome in exactly the opposite sense is trained, d. H. is open at the bottom and with the top Floor area is provided. The metal sheets can be successively connected to the plastic structure by means of a joining tool become. Alternatively, a tool can also be used that over several joining tools on opposite ones Tool sides, with which the sandwich structure shape and is obtained non-positively in one operation, whereby on the Retract and press the stamp on the opposite side.

In further embodiments, the aforementioned domes containing composite components in their manufacture on the Use of mutually adjacent stamps or on corresponding openings on each side of the cathedral are dispensed with become. In these cases it is advisable to change the thickness of the The plastic structure at the joint should not be too thin.

The invention is described in more detail below with the aid of the drawing explained.

It shows:

Fig. 1.1, 1.2 and 1.3 a metallic base body (1), a plastic structure (2) and a joining tool (3) in the region of the junction before, during and after the joining, the joining tool radius smaller the thickness of the composite of metal component, and as Plastic structure at the joint,

Fig. 2.1, 2.2 and 2.3 a metallic base body (1), the plastic structure (2) and a joining tool (3) in the region of the junction before, during and, after joining with positive and non-positive connection of metal member and plastic structure whereby the Joining tool radius is greater than the thickness of the composite of metal component and plastic structure at the joint,

Fig. 3 composite structure of Fig. 2.3, has been pushed at the projecting edge of the metal collar with a punch tool (4) towards the bottom of the plastic structure,

Fig. 4.1 and 4.2 a metallic base body (1) and the plastic structure (2) in the area of the joint after joining with positive and non-positive connection, whereby the joining tool radius in the range of the thickness is the composite of metal component and the plastics structure at the joint and wherein the metal edge collar is pressed with a stamping tool ( 4 ) towards the underside of the plastic structure,

Fig. 5 is a composite component made of a metal round body (1) and a plastics structure (2) with two joining points after the joining operation, the joining tools have been performed (3) in non-parallel alignment,

Fig. 6 is a metal component ( 1 ) with a U-shaped profile, which is connected to a plastic structure ( 2 ) in the form of a base plate to 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 ).

From the view in Fig. 1.1 a metal member (1) and a plastics structure (2) in the region of the joint is apparent prior to the joining operation. The joining tool ( 3 ) is reproduced as part of the overall tool before the actual joining operation. Apparent from the illustration according to FIG. 1.1 to 1.3 Furthermore, the wall thickness of the plastic structure between top and bottom at the joint as well as the maximum radius of the region of the joining tool, which penetrates into the composite structure more apparent. The composite structure rests on two supports ( 9 ) and is locked by two supports ( 10 ).

Fig. 2.1 to 2.3 show a metal basic body and the plastic structure in the area of the joint after joining in positive and non-positive connection. In this case, the joining tool has completely penetrated the plastic structure. A metal collar protrudes beyond the bottom of the plastic structure. Furthermore, the base bearing the plastic structure shows in the area of the joint an outlet ( 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 tensions or claws the metal edge in the plastic wall, creating a particularly permanent, positive and non-positive connection.

Fig. 4.1 and 4.2 show a composite component, wherein the metal rim flange formed corresponds approximately to the thickness of the composite member at the joint. With the aid of a mandrel-like stamping tool ( 4 ), the metal edge lying against the plastic structure has been widened from the side of the plastic structure underside. A similar result can also be achieved by using the actual joining tool ( 3 ) to perform a gyroscopic movement before reaching the maximum penetration depth, the longitudinal axis of the joining tool roughly describing the shape of a double cone.

Fig. 5 shows a composite component having two adjacent joints, wherein the respective joining tools are not aligned perpendicular to the respective joint face and extend the joining directions are not parallel. In this way, a particularly positive and non-positive connection is obtained.

Fig. 6 shows a U-shaped metal structure (1) having together with a rib structure (5) plastic bottom plate (2) forming a composite component. At the rib crossing points, the plastic structure has domes ( 7 ), the base plates of which lie on the inside against 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 are, for example as parts or component parts in the Automobile, aircraft or shipbuilding or in the manufacture of Furniture, household or electrical appliances. Applications in Automotive construction z. B. front end modules, front end supports, seat shells, Seat structures, instrument panels, door function carriers, Door function modules, tailgates or side doors.

The composite components presented have compared to the known Hybrid components have the advantage that the plastic structure here can be designed largely free of restrictions, since the Plastic structure according to the present invention in one separate production step can be manufactured. Subsequently the plastic structure according to the invention can be more load-bearing are designed as such from the prior art. This Advantage is expressed in the composite component obtained by higher Rigidity or strength with a comparable component weight out. Can be done without much effort, if necessary also manually or semi-automatic, joints also in poorly accessible Component positions are created. There are several joints in a component in front, the joining surfaces can be any to each other be arranged without thereby producing the Composite component would be difficult or series production no longer in Question would come.

Another advantage is that there are no additional Processing steps, e.g. B. gluing steps, short Have cycle times achieved in series production. Of There are no additional parts or components for that Joining of plastic structure and metal component required. In addition, the method according to the invention is overall less sensitive to deviations in the positioning of Stamped edge and plastic structure. In addition, any Plastic structures, regardless of the manufacturing process used be, with fiber-reinforced plastics equivalent are suitable.

Claims (16)

1. A method for producing a composite component from at least one metal component and at least one plastic structure, characterized in that 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 Joining points through the metal component and through or at least into the plastic structure and this is removed by an opposite movement again from the recess or opening formed in the composite component. 2. The method according to claim 1, wherein the one or more joining tools essentially perpendicular to the surface of the Joints are performed. 3. The method according to claim 1, characterized in that one at least two not aligned parallel to each other Joining tools through the metal component and through or at least in the plastic structure drives. 4. The method according to claims 1 to 3, characterized characterized in that the plastic structure at least during the joining process a higher temperature in the area of the joint than Has room temperature. 5. The method according to claims 1 to 4, characterized characterized that the joining tool when entering or Penetration of metal component and / or plastic structure at least is temporarily rotated around its own axis. 6. The method according to claims 1 to 5, characterized characterized that the joining tool after reaching the maximum Penetration or penetration depth when running out of the recess or opening at least temporarily rotated around its own axis becomes. 7. The method according to claims 1 to 6, characterized characterized that the joining tool when reaching the maximum Depth of penetration or penetration or when ingested or during the opposite movement a pendulum, wobble or Performs gyro motion. 8. The method according to claims 1 to 7, characterized characterized in that the maximum diameter of that area of the Joining tool that penetrates into the composite structure or that at the level of the surface of the metal component Reaching the maximum depth of penetration or penetration is at least twice the thickness of the Composite component at the joint. 9. The method according to claim 8, characterized in that one after removing the joining tool from the opening of the Side of the plastic structure with a stamp, hammer or joining tool creates an undercut or this strengthened. 10. The method according to claims 1 to 9, characterized characterized that the joining tool one towards the piercing end represents rejuvenating thorn. 11. The method according to claim 10, characterized in that the Longitudinal section has an asymmetrical shape. 12. The method according to claims 1 to 11, characterized characterized in that the joining tool in its penetration or Piercing area has a thread. 13. The method according to claims 1 to 12, characterized characterized in that the joining tool in its penetration or Piercing area of the shape of a self-tapping or corresponds to the thread-forming screw. 14. The method according to claims 1 to 9, characterized characterized in that the joining tool in its penetration or Piercing area in the form of a slot or Phillips screwdriver. 15. Composite components, obtainable by a process according to Claims 1 to 14. 16. Use of the composite components according to claim 15 as components or component components in automotive, aircraft or Shipbuilding or in the manufacture of furniture, household or electrical appliances.