DE102018204407A1 - Function-integrated temperature control in steel-plastic hybrids with thermally conductive fillers - Google Patents

Abstract

The present invention relates to a thermoformable, platinum or strip-shaped semi-finished product for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, comprising at least one platinum- or strip-shaped metal sheet and at least one on the metal sheet cohesively applied thermoplastic or thermosetting plastic layer, wherein the at least one thermoplastic or thermosetting plastic layer contains at least one of the heat conductivity of the plastic layer increasing filler and the at least one filler is present either over the entire plastic layer or in defined portions of the plastic layer in anisotropic distribution, a method for producing such a semi-finished product and a method for producing a three-dimensionally shaped hybrid component in metal / plastic composite.

Description

Technical area

The present invention relates to a thermoformable, platinum or strip-shaped semi-finished product for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, comprising at least one platinum- or strip-shaped metal sheet and at least one on the metal sheet cohesively applied thermoplastic or thermosetting plastic layer, wherein the at least one thermoplastic or thermosetting plastic layer contains at least one of the heat conductivity of the plastic layer increasing filler and the at least one filler is present either over the entire plastic layer or in defined portions of the plastic layer in anisotropic distribution, a method for producing such a semi-finished product and a method for producing a three-dimensionally shaped hybrid component in metal / plastic composite.

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, a side impact beam or a battery box in electric vehicle concepts. One approach to achieving such lightweight components is to combine different materials together.

Further, materials having the above-mentioned properties are to be provided with other functions, for example, heat-trapping property so as to cool components or aggregates by rapidly dissipating heat through these materials. At the same time appropriately functionalized materials should be easy to work with, in particular, they should be easily reshapeable, so that the greatest possible treasure is accessible.

From the prior art materials are known in which materials with good mechanical properties are combined with functionalized plastics.

WO 2014/118210 A1 discloses a composite material in which a plastic, a metal, a ceramic mass, wood, glass or textile fibers is applied to a fiber composite material by means of a copolyamide-based plastic layer. The fiber composite material is based on a thermoplastic material and may contain fillers such as talc or chalk.

WO 2017/102943 A1 discloses a plastic-metal hybrid material in which a polyamide or a polyamide-containing composition is applied to a metal sheet as a plastic. The polyamide-containing layer may contain fillers, for example glass beads, glass flakes, kaolin, talc, mica, wollastonite, calcium carbonate, silica or potassium titanate.

US 2015/0361304 A1 also discloses a metal-plastic hybrid material. This is obtained by applying a plastic to the surface of the metal. The plastic layer may contain fillers, for example talcum powder or chalk.

DE 10 2010 039 270 A1 discloses a metal-plastic composite component, which has a metal layer as a decorative side, on the back of a, preferably foamed, plastic layer is present. This plastic layer may contain additives such as talc.

Starting from this prior art, it is an object of the present invention to provide a semifinished product for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, which not only has advantageous mechanical properties but also very good thermal conductivity. In particular, the semifinished products according to the invention compared to the materials known from the prior art have an optimized structure to increase the thermal conductivity, and to reduce the necessary amount of thermally conductive fillers by optimizing the structure of the plastic layer or to direct the heat targeted / led on , This should make it possible to produce corresponding hybrid components with high load capacity at low weight and high thermal conductivity significantly cheaper than is possible with the method of the prior art.

These objects are achieved by the inventive thermoformable, platinum or ribbon-shaped semi-finished product for producing a three-dimensionally shaped hybrid component in the metal / plastic composite having at least one platinum or strip-shaped metal sheet and at least one on the metal sheet cohesively applied thermoplastic or thermosetting plastic layer, wherein the at least a thermoplastic or thermosetting plastic layer contains at least one filler which increases the thermal conductivity of the plastic layer and the at least one filler is present either in anisotropic distribution over the entire plastic layer or in defined subregions of the plastic layer.

The objects are further solved by the inventive method for Production of a thermoformable, platinum or ribbon-shaped semi-finished product according to the invention, wherein the at least one thermoplastic or thermosetting plastic layer containing at least one filler is applied to at least one platinum or strip-shaped metal sheet such that the at least one filler either over the entire plastic layer or in defined sub-areas of Plastic layer is present in anisotropic distribution, by the inventive method for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, wherein a semi-finished product according to the invention is used, wherein the coupling layer formed as thermoplastic or thermosetting plastic layer by injection molding, compression molding, extrusion or thermal pressing an additional structural body is integrally formed from plastic, and by the use of a semifinished product according to the invention for producing a dreidime nsional shaped hybrid component.

The semifinished product according to the invention has at least one sheet-metal or strip-shaped metal sheet.

In principle, according to the invention, it is possible to use all metal sheets which appear suitable to the person skilled in the art. In a preferred embodiment of the present invention, the metal sheet of the semifinished product according to the invention is made of a steel material, particularly preferably of dual-phase steel or another lightweight structural steel. A steel material is characterized by good formability and high strength. The microstructure of dual-phase steel preferably consists of a soft, ferritic matrix in which a second, hard, predominantly martensitic phase is embedded island-shaped. The ferrite content is preferably up to 90%. In addition to martensite, portions of retained austenite and bainite may also be present. Sheets made of dual-phase steel are particularly suitable for cold forming with a high ironing rate for the production of strength-relevant structural elements and body parts. Hot-rolled dual-phase steel has particular advantages in the weight-saving production of components such as profiles, body reinforcements and chassis parts. After a corresponding heat treatment, e.g. the so-called bake hardening treatment, additional strength gains of, for example, over 30 MPa are achieved.

The at least one metal sheet of the semifinished product according to the invention has, for example, a thickness of 0.1 to 2.5 mm, preferably of 0.1 to 1.0 mm, particularly preferably of 0.25 to 0.8 mm.

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.

Instead of a metal sheet of steel material, the semifinished product according to the invention may also have a metal sheet of magnesium or aluminum.

The semifinished product according to the invention has at least one thermoplastic or thermosetting plastic layer cohesively applied to the metal sheet, the at least one thermoplastic or thermosetting plastic layer containing at least one filler increasing the thermal conductivity of the plastic layer and the at least one filler either over the entire plastic layer or in defined subregions of the plastic layer in anisotropic distribution. In principle, any thermoplastic or thermosetting plastic known to the person skilled in the art or mixtures thereof can be used in the semi-finished product according to the invention.

For example, the present at least one thermoplastic material is selected from the group consisting of polyolefins such as acrylonitrile-butadiene-styrene (ABS), polymethyl (meth) acrylate (PM (M) A), polyethylene (PE), polypropylene (PP), polystyrene ( PS), polyvinyl chloride (PVC), polyamides (PA), polycarbonates (PC), polyesters such as polyethylene terephthalate (PET), polylactate (PLA), polyurethanes (PU), polysulfides (PS), polyetheretherketones (PEEK), polyarylenes, aromatic polyesters, Polyaramids such as poly-m-phenylene isophthalamide (PMI), polyaramid fibers, heterocyclic polymers such as polyimides, polybenzimidazoles, polyetherimides, liquid crystal polymers (LCP Liquid Crystalline Polymers), fluoropolymers, perfluorooxyalkane (PFA), polyphenylenes, thermoplastic elastomers, and mixtures thereof.

By-product thermosetting plastics are 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), polyesters (PES), Polyurethanes (PU), unsaturated polyesters (UP), any mixtures, compounds and functionalized variants thereof.

Further preferred thermosetting plastics are selected from the group consisting of partially crosslinked (bi-stage) polymers, which finally obtain their final properties by chemically, thermally, catalytically and / or photolytically initiated polymerization, and mixtures thereof.

More preferably, the one thermoplastic resin according to the invention is a thermoplastic elastomer selected from the group consisting of thermoplastic polyurethanes (TPU), 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), blends, compounds and functionalized variants thereof ,

The present invention therefore preferably relates to the semi-finished product according to the invention, wherein the at least one thermoplastic is selected from the group consisting of polyolefins such as acrylonitrile-butadiene-styrene (ABS), polymethyl (meth) acrylate (PM (M) A), polyethylene (PE ), Polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), polyamides (PA), polycarbonates (PC), polyesters such as polyethylene terephthalate (PET), polylactate (PLA), polyurethanes (PU), polysulfides (PS), polyetheretherketones (PEEK), polyarylene, aromatic polyesters, polyaramides such as poly-m-phenylene isophthalamide (PMI), polyaramid fibers, heterocyclic polymers such as polyimides, polybenzimidazoles, polyetherimides, liquid crystal polymers (LCP Liquid Crystalline Polymers), fluoropolymers, perfluorooxyalkane (PFA), polyphenylenes, thermoplastic elastomers and mixtures thereof.

The present invention preferably relates to the semifinished product according to the invention, wherein the 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), polyesters (PES), polyurethanes (PUR), unsaturated polyesters (UP), any mixtures, compounds and functionalized variants thereof,
or is selected from the group consisting of partially crosslinked (bi-stage) polymers, which finally obtain their final properties by chemically, thermally, catalytically and / or photolytically initiated polymerization, and mixtures thereof.

The present invention also preferably relates to the semi-finished product according to the invention, wherein the at least one thermoplastic resin is a thermoplastic elastomer selected from the group consisting of thermoplastic polyurethanes (TPU), 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 ), Mixtures, compounds and functionalized variants thereof.

The cohesively applied to the metal sheet thermoplastic or thermosetting plastic layer has, for example, a thickness of 0.01 to 2 mm, preferably from 0.05 to 1.0 mm, particularly preferably from 0.05 to 0.1 mm. For the case according to the invention that the plastic layer is formed from a plurality of individual layers, said thicknesses apply to the entire plastic layer.

According to the invention, the at least one thermoplastic or thermosetting plastic layer contains at least one filler which increases the thermal conductivity of the plastic layer.

In principle, according to the invention, it is possible to use all fillers known to the person skilled in the art which are suitable for increasing the thermal conductivity of the plastic layer.

Preferably, the at least one filler present in the plastic layer is selected from the group consisting of metal particles, for example Cu, Ag, Au, Ti, Zr, Ni or mixtures thereof, carbon black, carbon, graphites, carbon fibers, nanotubes, fullerenes, conductive ceramics, for example Superconductors, natural products, artificially generated, for example doped, conductive components and mixtures thereof.

More preferably, the at least one filler present in the plastic layer is in the form of fibers, spherical particles, irregularly shaped particles and mixtures thereof.

According to the invention, the at least one filler is present in principle in an amount which is sufficient to impart a sufficiently high thermal conductivity to the plastic layer according to the invention. For example, the plastic layer contains 0.1 to 99 wt .-% of the at least one filler.

According to the invention, the at least one filler is present either over the entire plastic layer or in defined subregions of the plastic layer in anisotropic distribution.

According to the invention, "in defined subregions of the plastic layer" means that the at least one filler is not present in the entire plastic layer, but only in some areas, for example, the at least one filler is preferably present in a partial area, which is 0.1 to 95 area% on the total area of the plastic layer.

The term "anisotropic distribution" is known per se to those skilled in the art. According to the invention, "in anisotropic distribution" means that the at least one filler is present in different concentrations along at least one spatial direction of the plastic layer.

In a preferred embodiment of the present invention, the at least one filler is present in different concentrations along the spatial direction, which is perpendicular to the metal sheet and the plastic layer. For example, the concentration in the plastic layer on the metal sheet may be highest and decrease as the distance within the plastic layer to the metal sheet increases. Furthermore, the concentration in the plastic layer adjacent to the metal sheet may be lowest and increase as the distance within the plastic layer to the metal sheet increases. Furthermore, the concentration in the plastic layer adjacent to the metal sheet may be lowest, increase, and then decrease again, the greater the distance within the plastic layer to the metal sheet.

In a further preferred embodiment of the present invention, the at least one filler is present in different concentrations along the spatial direction parallel to the metal sheet and the plastic layer. For example, the concentration in the plastic layer may decrease parallel to the metal sheet, increase, decrease and then increase or increase again and then decrease again.

More preferably, the concentration of the at least one filler within a distance of 0.0001 to 10 mm, preferably 0.001 to 5 mm, in the plastic layer of 0.01 to 99 wt .-%, preferably 1 to 90 wt .-%, on 0 to 1 wt .-%, preferably 0.1 to 1 wt .-% decrease.

In a further preferred embodiment, the concentration of the at least one filler within a distance of 0.001 to 10 mm, preferably 0.01 to 9 mm, in the plastic layer from 0 to 0.001. Wt .-%, preferably 0.1 to 1 wt .-%, to 5 to 99 wt .-%, preferably 10 to 70 wt .-% increase.

In a preferred embodiment of the semi-finished product according to the invention, there are two or more thermoplastic or duroplastic plastic layers which form the entire thermoplastic or thermoset plastic layer.

In this embodiment, it is further preferred that in each of the existing plastic layers there is an anisotropy described above, wherein these individual anisotropies may be the same or different.

In this embodiment, it is also possible that there is no anisotropy in each of the existing plastic layers, but that there is an anisotropy over the entire plastic layer due to the fact that different concentrations of at least one filler are present in the individual plastic layers. The concentrations in the individual layers may be, for example, 50 to 90 wt .-% in the layer with the highest concentration to 0 to 10 wt .-%, preferably 0.001 to 100 wt .-%, in the layer with the lowest concentration.

The cohesive application of the at least one thermoplastic or thermosetting 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. Such methods are known per se to the person skilled in the art and, for example, in US Pat DE 10 2013 109616 A1 described.

Before the application and / or during the application of the at least one plastic layer to the metal sheet, the at least one filler may be added to the thermoplastic or thermosetting plastic by methods known to those skilled in the art, for example compounding.

The anisotropy of the at least one filler present according to the invention at least in partial regions of the plastic layer can be obtained, for example, by changing, ie increasing or decreasing, the concentration of the at least one filler in the thermoplastic or thermoset plastic during the application. It is according to the invention also possible that a plurality of plastic layers are applied, wherein each individual plastic layer has a different concentration of at least one filler, so that the present invention at least in some areas anisotropy on the formed the individual plastic layers formed overall layer.

If at least one thermosetting plastic is applied according to the invention, one or more steps are preferably carried out after the application of the plastic layer of a thermosetting plastic in order to harden the thermosetting plastic, for example the polymerization is initiated chemically, thermally and / or photolytically.

In a preferred embodiment, the present invention relates to the semifinished product according to the invention, wherein the side of the metal sheet, on which the thermoplastic or thermosetting plastic layer is applied, has a surface which improves the 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 an adhesion-promoting layer in a coil coating, dip or drop coating process. The adhesion-promoting layer contains, for example, silanes, titanates, zirconates, aluminates, phosphoric esters, phosphates or mixtures thereof.

Furthermore, the adhesion mediation z. B. by mechanical, physical or chemical modification and / or activation such as surface enlargement, roughening, polarization, hydroxylation, charge transfer, cleaning, degreasing o. Ä. The metal surfaces take place. An example would be the application of an aqueous solution with inorganic and organic constituents, which may be acidic or basic depending on the metal, which allows a pickling and roughening of the surface and even the thinnest oxide layers separates from the metal. On the metal surface, the adhesion promoter which consists of polar and nonpolar groups, separates. While the polar regions are oriented towards the metal surface, the non-polar regions of the adhesion promoter allow the attachment to the polymer components.

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, aluminum, zinc alloys or aluminum alloys in combination with silicon and / or magnesium. The present invention therefore preferably relates to the semi-finished product 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 semifinished product according to the invention is provided with a corresponding surface coating and used, it is advantageously better protected against corrosion.

In experiments carried out by the applicant, it has been shown that a semifinished product according to the invention, whose metal sheet and plastic layer have thicknesses in the stated ranges, is well deep-drawable in the deepening test according to Erichsen at room temperature and mold temperature of 100.degree. Serving as a coupling layer thermoplastic or thermosetting plastic layer flows during deep drawing of the semifinished product according to the invention with the metal sheet and does not lose its liability.

The function of the thermoplastic or thermosetting plastic layer (coupling layer) of the semifinished product according to the invention is that it can be reliably bonded with a large number of other plastics, without the application of additional 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.

Examples of thermoplastic, thermoset plastics or thermoplastic elastomers which can be used according to the invention as a structural body which is injection-molded onto the plastic layer are thermoplastic polymers selected from the group consisting of polyolefins, such as acrylonitrile-butadiene-styrene (ABS), polymethyl (meth) acrylate (PM ( M) A), polyethylene (PE), polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), polyamides (PA), polycarbonates (PC), polyesters such as polyethylene terephthalate (PET), polylactate (PLA), polyurethanes (PU ), Polysulfides (PS), Polyether ether ketones (PEEK), polyarylene, aromatic polyesters, polyaramides such as poly-m-phenylene isophthalamide (PMI), polyaramid fibers, heterocyclic polymers such as polyimides, polybenzimidazoles, polyetherimides, liquid crystal polymers (LCP Liquid Crystalline Polymers), fluoropolymers, perfluorooxyalkane (PFA), polyphenylenes , thermoplastic elastomers and mixtures thereof,
thermosetting plastics 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), polyesters (PES), polyurethanes ( PUR), unsaturated polyesters (UP), any mixtures, compounds and functionalized variants thereof,
or selected from the group consisting of partially crosslinked (bi-stage) polymers which are finally obtained by chemically, thermally, catalytically and / or photolytically initiated polymerization, and mixtures thereof,
or thermoplastic elastomers selected from the group consisting of thermoplastic polyurethanes (TPU), 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 (US Pat. BR), acrylonitrile / methyl methacrylates (A / MMA), butyl rubbers (IIR), styrene-butadiene styrenes (SBS), polyether block amides (PEBA), blends, compounds and functionalized variants thereof.

1. 1. Platinen- oder bandförmiges Halbzeug konfektionieren (Zuschneiden);
2. 2. Zugeschnittenes Halbzeug zu einem Umformwerkzeug mit integriertem Spritzgießaggregat transportieren und einlegen;
3. 3. Umformen und Hinterspritzen des Halbzeugzuschnitts in einem Schritt.

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. The semifinished product according to the invention makes it possible to considerably reduce 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. For example, the automobile manufacturer or component supplier with the semifinished product according to the invention has, in particular, the possibility of producing a three-dimensionally shaped hybrid component by the following process steps:

1. 1. Assemble blank or ribbon-shaped semi-finished products (cutting);
2. 2. Transport cut semi-finished product to form a forming tool with integrated injection molding unit and insert it;
3. 3. Forming and injection molding of the semi-finished blank in one step.

An advantageous embodiment of the semifinished product according to the invention is characterized in that the plastic layer (coupling layer) does not completely cover the side of the metal sheet on which it is applied, but partially covers it. This embodiment is particularly useful if the hybrid component to be produced, for example, only partially a strength and / or stiffness-increasing rib structure made of plastic or only in some areas a heat-dissipating effect is desired. 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 heat dissipating effect.

A further advantageous embodiment of the semifinished product according to the invention is that the thermoplastic or thermosetting plastic layer is made double, wherein between the two plastic layers one, in particular 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 the invention, it is possible here for one or both plastic layers to contain at least one filler which increases the thermal conductivity of the plastic layer and for the at least one filler to be present either in anisotropic distribution over the entire plastic layer or in defined subregions of the plastic layer.

According to a further advantageous embodiment, the plastic layer (coupling layer) of the semifinished product 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 semifinished product 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). Also, by this configuration, the strength and rigidity of the hybrid component to be produced can be increased significantly with constant or even reduced total weight and gleichbeliebender or even increased heat dissipating effect. In this case, according to a further embodiment, the organic sheet on his the Sheet metal facing away from be coated with at least one second metal sheet. From such a semi-finished product, it is possible to produce particularly lightweight and at the same time very strong and stiff hybrid components with a correspondingly heat-dissipating effect, in particular if the organic sheet contains carbon fibers according to a preferred embodiment. 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 half-finished product according to the invention designed in this way, it is advantageously possible to produce hybrid components which have structural bodies produced on both sides of plastic, in particular ribbed bodies, without an application of adhesive.

Another advantageous embodiment of the semifinished product 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 formed as a coupling layer for cohesive, adhesive-free connection at least one made of plastic or manufactured structural body. Also from such a semifinished product 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 semifinished product 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 semi-finished products designed in accordance with the invention, lightweight hybrid components with high strength and rigidity and a corresponding heat-dissipating effect can be produced inexpensively. The same applies to a further embodiment of the semifinished product according to the invention, in which the second plastic layer is completely or partially coated with at least one organic sheet.

According to a further embodiment of the semifinished product 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 semifinished product and possibly also during the forming of the semifinished product. 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 semifinished product during forming.

The semi-finished product according to the invention is preferably formed as a flat product. It can be processed by means of a platen press in a static process, an interval heating press in a batch process or in a continuous process in a laminating plant, for example a double belt press. The process parameters are set in each case specifically for the semi-finished product to be produced. Depending on the semifinished product variant, panels can be cut from this, or the band-shaped semi-finished product can be rolled up into a coil.

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

As already stated, the semifinished product according to the invention makes it possible to produce a three-dimensionally shaped hybrid component made of metal and plastic with a structural body, preferably a ribbed body, of plastic without application of adhesive. This significantly simplifies the production of the hybrid component.

A preferred embodiment of the method according to the invention is that the semifinished product is formed into a three-dimensional shape prior to molding of the structural body. The forming 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 semifinished product by means of a forming tool having at least one integrated Spritzgießkavität and at least one opening into the Spritzgießkavität injection molding, is transformed. This refinement offers the possibility of reducing the number of process steps for producing the hybrid component, in that the forming of the semifinished product or semifinished product blank and the injection molding of the coupling layer for producing the structural body, preferably fin body, are carried out in the same process step.

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

A further variant of the method according to the invention is that the semi-finished product is formed by roll forming, during or after the forming of the semifinished product, a rotatable, wheel-shaped tool is used for molding the structural body, and the tool with a profile having at least one cavity for pressing and Three-dimensional shapes of a plastic material is provided. With this embodiment of the method, in particular designed as a profile carrier hybrid components of the type mentioned can be effectively produced in mass production.

According to a further embodiment of the method according to the invention, at least one integral flange is formed on the hybrid component, which has the thermoplastic layer formed as a coupling layer, wherein a further executed as a metal / plastic composite hybrid component or an organic sheet is added by welding to the plastic layer. 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 connection of the hybrid components designed as half shells or of the organic sheet with a single hybrid component can be produced, for example, by friction welding, spot welding, ultrasonic welding, etc.

According to a third teaching of the present invention, the semifinished product according to the invention is advantageously used for producing a three-dimensionally shaped hybrid component as a component for a vehicle, aircraft, ship or building. Advantages arise namely by the semifinished product according to the invention everywhere, where in addition to a weight saving and a high heat dissipation effect is required and this hybrid components of the type mentioned in as few process steps to be produced.

The present invention therefore also relates to the use of the semifinished product according to the invention for producing a three-dimensionally shaped hybrid component as a component for a vehicle, aircraft, ship, rail vehicle or in mechanical engineering, in the energy industry or in construction.

Furthermore, the present invention also relates to the use of a semifinished product according to the invention for producing a three-dimensionally shaped hybrid component.

The invention will be explained in more detail with reference to figures and embodiments.

list of figures

• 1 shows a hybrid material according to the invention, wherein the polymer layer contains a filler (additive) in an isotropic distribution.
• 2 shows a hybrid material according to the invention, wherein the polymer layer contains a filler (aggregate) layered in anisotropic distribution.
• 5 shows a hybrid material according to the invention, wherein the polymer layers have a filler (additive) in different concentrations, so that an overall anisotropic distribution results.
• 4 shows a hybrid material according to the invention, wherein the polymer layer has a filler (aggregate) with a concentration gradient, so that an anisotropic distribution results.
• 5 shows a hybrid material according to the invention, wherein the polymer layer has a filler (aggregate) in a horizontal preferred direction, for example, for heat conduction, in anisotropic distribution.
• 5a shows a hybrid material according to the invention, wherein the polymer layer has a filler (aggregate) in several layers in a vertical preferred direction, for example, for heat conduction, in anisotropic distribution.
• 5b shows a hybrid material according to the invention, wherein the polymer layer a filler (aggregate) in several layers each in horizontal preferred direction, for example, for heat conduction, in anisotropic distribution.
• 5c shows a hybrid material according to the invention, wherein the polymer layer has a filler (aggregate) in several layers in diagonal preferred direction, for example, for heat conduction, in anisotropic distribution.

Industrial Applicability

The semifinished product according to the invention combines good mechanical characteristics and a high heat-dissipating effect, so that advantageous three-dimensionally shaped hybrid components can be produced as components for a vehicle, aircraft, ship or building.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• WO 2014/118210 A1 [0005]
• WO 2017/102943 A1 [0006]
• US 2015/0361304 A1 [0007]
• DE 102010039270 A1 [0008]
• DE 102013109616 A1 [0041]

Claims (17)

Deep-drawable, platinen- or band-shaped semi-finished product for producing a three-dimensionally shaped hybrid component in the metal / plastic composite having at least one platinum- or strip-shaped metal sheet and at least one on the metal sheet cohesively applied thermoplastic or thermosetting plastic layer, characterized in that the at least one thermoplastic or thermosetting Plastic layer contains at least one of the heat conductivity of the plastic layer increasing filler and that the at least one filler is present either over the entire plastic layer or in defined portions of the plastic layer in anisotropic distribution. Semi-finished product Claim 1 , characterized in that the side of the metal sheet, on which the plastic layer is applied, has a surface which improves the adhesion of the plastic layer. Semi-finished product Claim 1 or 2 , characterized in that the plastic layer is formed as a coupling layer for cohesive, adhesive-free connection of at least one plastic body produced or produced structural body. Semi-finished product Claim 3 , characterized in that the manufactured or manufactured structural body is formed of a thermoplastic and optionally fiber-reinforced plastic. Semi-finished product after one of Claims 1 to 4 , characterized in that two or more thermoplastic or thermosetting plastic layers are present, which form the entire thermoplastic or thermosetting plastic layer. Semi-finished product after one of Claims 1 to 5 , characterized in that the metal sheet is made of a steel material. Semi-finished product after one of Claims 1 to 6 , characterized in that the metal sheet has a thickness of 0.1 to 2.5 mm, preferably from 0.1 to 1.0 mm, particularly preferably from 0.25 to 0.8 mm. Semi-finished product after one of Claims 1 to 7 , characterized in that the at least one thermoplastic plastic is selected from the group consisting of polyolefins such as acrylonitrile-butadiene-styrene (ABS), polymethyl (meth) acrylate (PM (M) A), polyethylene (PE), polypropylene (PP) , Polystyrene (PS), polyvinyl chloride (PVC), polyamides (PA), polycarbonates (PC), polyesters such as polyethylene terephthalate (PET), polylactate (PLA), polyurethanes (PU), polysulfides (PS), polyetheretherketones (PEEK), polyarylenes, aromatic polyesters, polyaramides such as poly-m-phenylene isophthalamide (PMI), polyaramid fibers, heterocyclic polymers such as polyimides, polybenzimidazoles, polyetherimides, liquid crystal polymers (LCP Liquid Crystalline Polymers), fluoropolymers, perfluorooxyalkane (PFA), polyphenylenes, thermoplastic elastomers, and mixtures thereof. Semi-finished product after one of Claims 1 to 7 , characterized in that the 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), Polyesters (PES), polyurethanes (PUR), unsaturated polyesters (UP), any mixtures, compounds and functionalized variants thereof or is selected from the group consisting of partially cross-linked (bi-stage) polymers, which final properties by chemical, thermal , catalytically and / or photolytically initiated polymerization, and mixtures thereof. Semi-finished product after one of Claims 1 to 7 , characterized in that the at least one thermoplastic resin is a thermoplastic elastomer selected from the group consisting of thermoplastic polyurethanes (TPU), 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 (IR), styrene-butadiene styrenes (SBS), polyether block amides (PEBA), blends, compounds and functionalized variants thereof. Semi-finished product after one of Claims 1 to 10 , characterized in that the thermoplastic or thermosetting plastic layer has a thickness of 0.01 to 2 mm, preferably from 0.05 to 1.0 mm, particularly preferably from 0.05 to 0.1 mm. Semi-finished product after one of Claims 1 to 11 , characterized in that the at least one thermoplastic or thermosetting plastic layer at least partially covers the side of the metal sheet on which it is applied. Process for producing a thermoformable, platinum or ribbon-shaped semifinished product according to one of Claims 1 to 12 , characterized in that at least one thermoplastic or thermosetting plastic layer containing at least one filler is applied to at least one platinum or strip-shaped metal sheet, that the at least one filler is present either over the entire plastic layer or in defined portions of the plastic layer in anisotropic distribution. Method according to Claim 13 , characterized in that in two or more successive steps, two or more thermoplastic or thermosetting plastic layers are applied. A method for producing a three-dimensionally shaped hybrid component in the metal / plastic composite, characterized in that a semifinished product according to one of Claims 1 to 12 is used, wherein an integrally formed plastic structural body is integrally formed on the formed as a coupling layer thermoplastic or thermosetting plastic layer by injection molding, compression molding, extrusion or thermal pressing. Method according to Claim 15 , characterized in that the structural body to be formed is formed of a thermoplastic and optionally fiber-reinforced plastic. Use of a semi-finished product according to one of Claims 1 to 12 for producing a three-dimensionally shaped hybrid component.

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