DE10326768A1 - Combined internal high pressure forming and injection molding process for production of hybrid metal and plastic components involves hydroforming a sealed, fluid filled preform followed by plastic injection - Google Patents

Abstract

A preformed metal component (9) is filled with a non-compressible fluid and closed at both ends. The component is placed in a first cavity (18) of a molding tool (16,16.1,16.2,16.3), subjected to hydroforming and openings (14,15) created for plastic to enter. Tool rearrangement transfers the hydroformed component to a second cavity (20) where plastic is injected to form a hybrid component. During hydroforming, typically with water, pressure is applied to the component(9) according to the principle of hydraulic balance and the component shapes(11,12) are produced by punches which impinge in one or more areas. Hydroforming enlarges the component diameter. Tool(16,16.1,16.2,16.3) rotation is through 180[deg] during transfer of components between cavities(18,20). During injection plastic flows around the component and through the openings(14,15) to ensure positive connection between metal and plastic. Release of fluid may occur after completion of the hybrid component or by suction before the injection stage. All process stages may be realized in horizontally or vertically acting injection machines. Process variations for joining a hydroformed component and a plastic material involve: (a) placing a hydroformed metal component in a molding tool and injecting plastic into a cut-out of the component which is enlarged by the plastic pressure to form an undercut connection; (b) placing a plastic component with a expandable metal component inside it in a tool cavity, then through use of the internal high pressure forming process (IHU) creating a localized enlargement of the metal component diameter against the plastic component; and (c) a preformed metal component is filled with water, sealed at the ends and then reshaped by the IHU process in a molding tool through injection of plastic.

Description

The invention relates to a Process for the production of hybrid components made of plastic and hydroformed profiles.

Out WO 01/72495 A1 has become known a composite component and a method for its production. The composite component comprises a hollow profile base body which has a hollow profile cross section. At least one plastic element is firmly connected to the hollow profile base body, the plastic element being molded onto the hollow profile base body and its connection to the hollow profile base body at a discrete connection position by partially or completely encasing the hollow profile base body at several connection points with that for the plastic element molded plastic. According to the method for producing a composite component disclosed in this publication, the method steps for the internal high-pressure forming of the hollow profile base body are combined with those of injection molding for molding and molding the plastic elements, so that the forming of the hollow profile base body and the injection molding of the plastic elements on the same injection molding -Machine can be done.

Out EP 0 370 342 B1 lightweight components have become known which consist of a shell-shaped base body, the interior of which has reinforcing ribs which are firmly connected to the base body. The base body is ideally made of metal and the reinforcing ribs are made of molded, thermoplastic plastic. The reinforcing ribs are firmly connected to them at discrete points through openings in the base body through which the plastic flows during injection molding. The disadvantage of this method is that it is very complex and requires a great deal of effort in terms of tool maintenance.

A high proportion of rejects can therefore be frequently do not avoid. Moreover one needs for every new model variant or model change a new, at least complicated injection molding tool, what the process costs not inconsiderably more expensive. Series production is therefore often included imponderable Risky. With increased Light components also have a load compared to the composite components mentioned above with the same dimensioning of the cross sections and with comparable Component weight has the disadvantage of lower rigidity, in particular with torsional stress. Furthermore, they have the disadvantage of being less Energy capability in the event of sudden stress. These drawbacks will be mainly due to the buckling and buckling efforts of shell-shaped sheets when exceeded a critical load. The tendency to buckle and buckle strengthened when increasing the load the highly stressed joints between the bowl-shaped base body and the reinforcing ribs should break open.

From the DE 101 08 898 .1 has become known a method for forming drive components, with which drive components, such as. B. External gears on electrical drives. According to this method, components present as blanks are enclosed on the outside by a molding tool and are deformed by internal high-pressure forming. The wall of the blank takes on the contour of the molding tool. Before the final shaping, for example a toothing on the outer circumference of a blank consisting of plastic material, an enlargement of the diameter can be generated on the blank. Furthermore, areas made of solid material can remain within the blank made of plastic, which not inconsiderably improve the bending stiffness and torsional stiffness of the plastic component to be produced.

DE 196 17 219 A1 relates to a hollow shaft, in particular a camshaft for an internal combustion engine. This hollow shaft consists of a plurality of tubular bodies arranged one inside the other, which are successively inflated in an outer shape with an inner contour corresponding to the outer contour of the shaft by using the internal high-pressure forming process. The outer tubular body can consist of a material with better mechanical properties, while the inner tubular body can be made of a less expensive material. The inner cavity of the hollow shaft can be filled with a plastic material.

Out DE 197 24 623 A1 A threaded spindle has become known, into which additional functions can be introduced using the hydroforming process. In the axial direction, at least on an outer wall of the threaded spindle, different structures, such as. B. threads with different pitch, be it pointed and / or round and / or trapezoidal and / or rectangular thread. The structures can also be used as seamless, polygonal elements such as e.g. B. tubes and / or cams and / or gears.

A combination of hydroforming processes, in particular the hydroforming process (IHU) and injection molding z. B. for the production of steel or. Until now, producing aluminum tubes with plastic components in one component has had serious disadvantages. In principle, the presses for the IHU of the profiles and large plastic injection molding machines are very similar in their technical data relevant for the forming, but the IHU components had to be greased before the forming in order to reduce the friction. Another disadvantage of the IHU process is that the entire tool is in contact with the pressure medium comes. The IHU was usually carried out on horizontally oriented presses, while injection molding generally takes place on vertically arranged machines. Another disadvantage is that plastic components can generally not be cold formed.

Given the outlined technical The invention is based on problematic and the prior art shown the task is based on a method for producing hybrid components specify which of the advantages of function-integrating plastic components with those of the hydroformed components.

According to the invention, this object is achieved by Features of the claims 1, 16, 18 and 21 solved.

Leave with the solution proposed according to the invention the process of hydroforming metallic in one operation Components and injection molding combine component components made of plastic so that a hybrid component using the similarities of a manufacturing facility for hydroforming and an injection molding machine for Plastic material can be produced in one operation. According to the method according to the invention the friction between the component formed according to the hydroforming process and the Wall of the tool through one in the tool - which, for example, as a rotating mold can be formed - inserted Foil reduced. With that leaves greasing in an advantageous manner according to the IHU method Avoid the component to be deformed. Preformed can favor the IHU forming process Components made of metallic material with a pressure medium such as Water infested be, after which the ends of the preformed component made of metallic material be closed. This allows pressure to be applied to the preformed metallic component according to the principle of a hydraulic Scales, so that depending on the entry area from the hydroforming process used stamps the contour of the preformed component to be formed is achieved in the IHU process. At the same time as part of the IHU molding preformed components made of metallic material can the shape of the contour of the hybrid component to be produced generates breakthroughs be a positive fit between the preformed components made of metallic material and the one injected after hydroforming Allow plastic material. After the hydroforming has been completed of the preformed metallic component inside the tool it is moved in such a way that the contour is formed metallic component is positioned in an injection molding cavity.

Through that in the second cavity of the mold injected plastic material becomes the hydroformed component made of metallic material according to the position of the plastic injection openings encapsulated with plastic material. That the hydroformed cavity Component made of metallic material favors in advantageously the cooling of the plastic material in the mold, while at the same time the next preformed in the first cavity formed in the mold Component is formed from metallic material.

The method proposed according to the invention let yourself on both horizontal and vertical presses, d. H. injection molding machines carry out. With the proposed according to the invention Procedure leaves avoid greasing hydroformed components before forming. It is also avoided that the complete tool during hydroforming with the pressure medium, which is proposed in accordance with the invention Process inside the preformed metallic component Material is picked up, comes into contact.

With the solution according to the invention according to claim 17 leaves a connection between a hydroformed component and Manufacture plastic material, the hydroformed component in an injection mold is inserted and the heated plastic melt injected into a recess previously made in the hydroformed component becomes. Due to the entering plastic material, which with a higher one Injection pressure supplied the softer component expands so that a Undercut that sets for a firm and lasting Connection of the hydroformed component made of metallic material with the plastic material.

With the solution according to the invention according to claim 19 is a connection of a plastic component with one of these penetrating expandable component made of metallic material, where that in thin Wall thickness trained according to the IHU procedure expandable component after insertion into the mold and loading undergoes a radial expansion with an internal high pressure, so that its outer surface to the inside of a plastic component surrounding the expandable component snugly. By induction a targeted local Expansion of the expandable component made of metallic material in accordance with the IHU process Firm fit between the plastic component and the expandable that penetrates it metallic component reached.

In an advantageous development of the method for producing a hybrid component according to claim 1, the process steps of hydroforming the preformed component from metallic material, in which the contour of the preformed component is formed from metallic material and the injection of plastic material into a second cavity on the molding tool, are carried out clocked, so that one per IHU-Ver driving preformed component made of metallic material and a finished hybrid component can be produced. The change of position of the molding tool for carrying out the injection molding process after the IHU process is achieved by pivoting the molding tool about an axis of rotation. Since the preformed component made of metallic material is affected by a pressure medium inside and its ends are closed, the pressure can be applied to the preformed component made of metallic material during the hydroforming process according to the principle of the hydraulic balance, so that a corresponding Movement of stamping tools into the areas provided for this purpose allows the preformed component made of metallic material to be widened within the cavity of the molding tool. The final contour of the part can thus be formed from metallic material of the hybrid component to be produced.

That in the first cavity, which for the IHU molding process serves, inserted pre-formed component made of metallic material will be within one after the mold is closed or several stamp entry areas according to the entry movement and the entry pressure of the stamps are formed. When forming can in particular widen the diameter depending on the forming pressure can be achieved as part of the IHU process. In addition, during the IHU process inside the mold via retracting Punch on selected Areas of the hybrid component to be produced or openings holes or the like are formed in which in the further progress the process the plastic material is included. In this way will later injecting the plastic material into the second cavity of the mold achieved that between the hydroformed component and the plastic material to be injected a stable, stable positive connection formed. By the contained in the interior of the hydroformed component Print medium, such as. B. water, a faster cooling of the tempered fed as plastic melt via a Spritzgießkopf injected plastic material can be achieved, so that finished hybrid component can be removed faster from the mold.

Flowable plastic material injected into the second cavity in the form of a plastic melt, that the plastic material has openings or openings made by means of the hydroforming process were created on the component made of metallic material and establish a permanent positive connection between the Plastic and the metallic part of the hybrid component sets. breakthroughs and holes which can be produced in the component from metallic material, however, are not necessarily required.

The one inside the preformed component Print media can be used both during the IHU process as well during the subsequent injection molding in the preformed component or hydroformed component of the hybrid component remain.

Filling the component to be deformed metallic material can be part of the pre-deformation of the component made of metallic material. Alternatively, the print medium could be molded the contour of the hydroformed component can be extracted from it, however, which would have the disadvantage of a significant increase in cycle time. Further Is it possible, when performing of the proposed according to the invention Process on a vertically modified injection molding machine to let the print media run down without it comes into contact with the tool. According to the explanations shown of the pressure medium from the preformed or hydroformed component Made of metallic material is achieved in a combined IHU injection molding process the pressure medium does not match the injection molding cavity in which the plastic melt is injected, comes into contact.

Can be advantageously with the proposed according to the invention Process positive Connections between hydroformed cavities bodies reach from metallic material and from plastic material. The Expansion of a radially expandable that penetrates a plastic component tubular Body metallic material is by means of the proposed according to the invention Procedure possible. It leaves a partial and local achieve limited expansion of the shell of a tubular body, in particular a targeted local expansion in softer Areas of the component made of metallic material or in areas with a wall thickness targeted weakening have experienced.

Using the proposed method a combined IHU injection molding process can be almost ideal conditions for the injection molding process inside the mold, which is a first cavity for hydroforming and a second cavity for the injection molding contains to reach. By enclosing the print medium within the preformed Component made of metallic material, which is within the mold is shaped into the corresponding contour the elaborate and costly water treatment that was previously required was to be avoided, as dirt as well as fats and oils from the pressure medium can be kept away since this is within the preformed component made of metallic material Completely is encapsulated.

drawing

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

It shows:

1 a profile made of metallic material in the undeformed state,

2 a pre-shaped profile (blank) made of metallic material filled with pressure medium and closed ends,

3 the deformed profile made of metallic material with pressed ends into which penetrations for plastic material are introduced,

3.1 a blank made of metallic material before the IHU process,

3.2 an internal high pressure formed metal component after the IHU process,

3.3 an internal high pressure formed component after punching openings,

3.4 a friction-reducing layer applied to the component made of metallic material,

4 a movable mold plate with a first cavity and a second cavity,

4.1 - 4.6 a rotating plate shown with a first cavity and a second cavity 4 , a process sequence, which is carried out by means of the mold plate, being shown in the figure sequence,

5 a formed metallic component with a lateral recess according to a first connection variant,

6 into the hydroformed metallic component according to 5 injected plastic material to form a first connection variant,

7 the hybrid component in the final state with the head and foot area overmolded with plastic material,

8th a plastic component in its cavity, undeformed component made of metallic material according to a second connection variant,

9 the plastic component according to 8th with a radially expanded component made of metallic material to create a tight fit and

10 a perspective view of a plastic injection molding machine.

1 a profile made of a metallic material or an alloy of metallic materials with a thin wall thickness can be found.

Out 1 a component to be deformed 1 which can be obtained as a raw profile. This in 1 shown component to be deformed 1 holds a thin-walled component jacket 2 , so that this is suitable for IHU processes. This in 1 shown component to be deformed as raw profile 1 includes a first open end 4 and a second open end 5 , The component jacket 2 of the component to be deformed delimits a cavity with a pressure medium 6 such as how water can be infested.

According to the illustration 2 is a preformed profile made of metallic material, which is filled with a pressure medium and is closed at both ends.

This in 2 shown, preformed component 9 Made of metallic material is slightly pre-bent mechanically and, due to its thin wall thickness, is suitable for hydroforming (IHU). After filling the cavity 3 of the mechanically preformed component 9 this is closed at its ends, so that there is a first closed end 7 and a second closed end 8th can be made by pressing. The inside of the preformed component 9 recorded media 6 , e.g. B. water, allows the application of an external pressure to the preformed component made of metallic material according to the principle of a hydraulic balance. The closed ends 7 or 8 of the preformed component 9 Made of metallic material, stamp areas that can be retracted or extended in a molding tool can be pressed further in flat form. The one in the cavity 3 of the preformed component 9 recorded supply of printing medium 6 , such as B. water, on the one hand allows the application of pressure and pressure distribution to the preformed component 9 as well as its contouring in accordance with the principle of the hydraulic balance and, last but not least, the heat dissipation from the further course of the process, the pre-deformed and subsequently molded component made of plastic material surrounding metallic material. By filling the cavity 3 of the preformed component 1 with water, a faster cooling of a finished hybrid component in the mold is favored, so that it can be removed more quickly from it.

3 shows the pre-formed profile groove pressed end areas, in which penetrations for plastic material are introduced.

From the representation according to 3 shows that stamp areas can be inserted into a mold 11.1 . 11.2 , a first stamp 11 (see 3.1 ) in the 2 areas designated as closed ends 7 and 8th are further shaped. These are pressed flat and also have perforated punches with openings 14 respectively. 15 Mistake. To avoid friction between the wall of the molding tool, in which the preformed component made of metallic material 9 is molded, is the component jacket 2 from a friction-reducing film 10 surrounded (compare 3.4 ).

By applying the external pressure and applying the pre-formed component 9 is further shaped and that inside the preformed component 9 Media supply taken from metallic material 6 , when applying external pressure according to the principle of the hydraulic balance below the first Stempeleinfahrbereiches 11 - to give an example - a widening of the diameter 13 achieved. In the 3 below the first stamp entry area 11 generated expansion of diameter 13 might as well be next to the second stamp entry area 12 of the molded component 9 made of metallic material. The breakthroughs created by inserting punching tools 14 respectively. 15 allow the plastic material later injected into a mold, these breakthroughs 14 . 15 to penetrate and in this way after cooling the plastic melt a positive, permanent plastic connection between the materials of a hybrid component 27 manufacture.

3.1 shows a component to be deformed, which is inserted into a first cavity of a mold.

The component to be deformed 1 which has a first closed end 7 is inside the first cavity 18 , A boundary surface 29 the first cavity 18 is through stamp areas 11.1 of a stamp 11 as well as the end faces 28.1 of cut stamps 28 educated. At the in 3.1 component shown 11 it is one and the same component whose halves with reference numerals 11 respectively. 12 are designated. The one in the stamp tool 11 . 12 , recorded cutting stamp 28 can e.g. B. be designed as a round pin. By shaping the stamp surface 11.1 of the stamp 11 becomes one with reference numerals 29.1 identified contour, which, after completion of the hydroforming process, the contour of the component to be deformed 1 certainly. The one with reference numerals 3 identified component cavity of the component to be deformed 1 can with a printing medium, such. B. water infested.

3.2 shows the component to be deformed after the IHU process.

From the representation according to 3.2 shows that this is in the first cavity 18 of the mold 16 inserted component 1 at its first closed end 7 is continuously deformed. By retracting the stamp 11 and 28 and creation of the stamp surfaces 11.1 . 12.1 and 28.1 on the component jacket 2 the pressure medium is displaced and the metallic component expands elsewhere 1 on (IHU process). By the retracting movement of the stamp tool 11 with cut stamps enclosed by these 28 is the first closed end 7 formed into a tongue-shaped area, which is about twice the material thickness of the component to be deformed 1 equivalent.

3.3 shows the component to be deformed 1 during a punching process.

From the representation according to 3.3 shows that the according 3.2 the lower region of the component to be deformed, formed by internal high pressure 1 with a first penetration 14 is provided. The end faces remain 11.1 . 12.1 of the stamp 11 in their position according to the position of these components 3.2 equivalent. With the in 3.3 The direction of the arrow entered is the movement of the die 28 clarifies with their retraction in the deformed material of the component to be deformed 1 an example of a circularly configured section is cut out. This is between the end faces 28.1 the cutting stamp 28 held and thus out of the deformed area at the first closed end 7 of the component to be deformed 1 separated out.

3.4 is a friction-reducing coating of a component to be deformed 1 refer to.

At the in 3.4 shown friction-reducing coating 10 For example, it can be a shrink film that is applied to the component jacket 2 the inside of the mold 16 component to be deformed 1 is applied. The friction reducing film 10 lies over the entire circumference of the component casing 2 so that the contact surface of the component to be deformed 1 inside the first cavity 18 of the mold 16 thanks to the friction-reducing film 10 and not directly through the component jacket 2 of the component to be deformed 1 is formed. In 3.4 is the component cavity 3 at the first open end 4 reproduced of the component to be deformed.

As shown 4 a movable mold can be seen which contains a first cavity suitable for the hydroforming process and a further second cavity for the injection molding process.

The related to the 1 to 3 The IHU process described takes place, for example, within a mold 16 , which allows a combined IHU injection molding process, whereby it is ensured that the pressure medium 6 with the one in the mold 16 trained injection molding cavity 20 does not come into contact. This in 4 Mold shown in a schematic representation 16 is preferably carried out on a modified injection molding machine oriented essentially in the vertical direction. The use of the mold 16 on a modified injection molding machine oriented essentially in the vertical direction, facilitates handling with regard to the removal of the pressure medium from a finished hybrid component 27 (compare illustration according to 7 ). In a vertically oriented injection molding machine, the pressure medium can act due to the effect of gravity 6 from the interior 3 of the completed hybrid component 27 drain down without using the molding tool 17 in particular to come into contact with its second cavity for injection molding. After performing the in 1 . 2 and 3 described forming process, the mold is moved, for example by a rotation thereof by 180 °. That within a first cavity suitable for hydroforming 18 recorded, in 3 shown fully molded component 9 metallic material is thereby in an injection molding cavity 20 of the mold 16 positioned.

Plastic injection molding is now used to inject plastic material that is in the form of a plastic melt at a higher temperature level into the second cavity 20 inside the mold 16 , During the injection molding process, the process can be carried out as shown 7 removable areas 21 and 24 on the fully formed component 9 Spray out of metallic material. According to the arrangement of the bullet points of the plastic material injected in flowable form, this can be the at the end regions of the fully contoured and molded component 9 Penetrations made of metallic material 14 or flow through 15. However, it is not absolutely necessary on the molded component 9 penetrations 14 respectively. 15 pre; a positive connection between the metallic component 9 and the plastic material can also be achieved by suitable external contouring of the area which is encapsulated by the plastic material in the injection molding process.

In contrast, become penetrations 14 respectively. 15 on the molded component 9 provided, the flowable plastic material passes through it, so that in the head area 21 or in the foot area 24 a form-fitting connection between the metallic material and the injected plastic material is achieved on the finished molded component made of metallic material. Due to the filling of the molded component 9 made of metallic material with a pressure medium 6 a faster cooling of a finished hybrid component 27 to reach.

During the injection of plastic melt into the designated areas of the second cavity 20 for injection molding on the mold 16 takes place, the next preformed component becomes the same 9 Hydroformed from metallic material.

With each cycle, a new pre-formed component is created 9 made of metallic material in the first cavity 18 of the mold 16 at the same time a finished hybrid component 27 whose completion is within the second cavity 20 of the mold 16 he follows.

The figure sequence of the 4.1 to 4.6 A process sequence of a multi-part mold can be seen.

From the representation according to 4.1 shows that the molding tool 16 , which is procured here as a molding plate, a first molding 16.1 , a pivoted second molded part 16.2 as well as a third molded part 16.3 having. In all molded parts 16.1 . 16.2 respectively. 16.3 of the mold 16 run sections of the first cavity 18 for the IHU process and the second cavity 20 for the injection molding process. The second molding 16.2 is about its axis of rotation 17 swiveling, whereas the first molded part 16.2 or the third molding 16.3 of the mold 16 are arranged stationary. With reference numbers 28 are the cutting punches with which the pre-formed component is made of metallic material 9 penetrations 14 respectively. 15 can be generated at one end.

4.2 shows the hydroformed component 9 and the creation of penetrations 14 at the first closed end 7 of the preformed component 9 made of metallic material. Using the retracting die 28 can penetrations at the first closed end 7 of the component to be deformed 1 are generated, which a favorable form fit between the in the second cavity 20 of the mold 16 produce sprayed plastic material. Simultaneously to retract the cutting punch 28 into the metallic material of the preformed component 9 to create the penetrations 14 are in the head area 21 or in the foot area 24 in the second cavity 20 flowable plastic melt is injected for the component in the injection molding process, with which the plastic head part 21 or the plastic foot part 24 be formed. The first molded part lies during this process step 16.1 , the second molding 16.2 as well as the third molding 16.3 at their joints.

4.3 it can be seen that the in 4.2 in the second cavity 20 manufactured hybrid component from the second cavity 20 is removed. This component is removed from the mold and is therefore no longer inside the second cavity 20 of the plate-shaped configured mold 16 ,

From the representation according to 4.4 can be seen that the relative to the first molded part 16.1 or the third molding 16.3 movably arranged molded part 16.2 in a stroke 16.4 executes, whereby the molding tool 16 Splits. That in the first cavity 18 of the movable second molded part 16.2 pre-deformed workpiece made of metallic material, which is already at the first closed end 7 penetrations 14 has during the lifting movement 16.4 through the first cavity 18 fixed.

4.5 can be seen that the in the stroke direction 16.4 moving, relatively movable second molding 16.2 now around its axis of rotation 17 according to the sense of rotation 19 is pivoted. The pre-deformed component remains during the swiveling process 9 made of metallic material within the first cavity 18 and therefore becomes during the rotation of the second molded part 16.2 around the axis of rotation 17 pivoted. At its first closed end 7 are in 4.5 by means of the cutting stamp 28 attached penetrations 14 to recognize. Also in the upper area, ie in the area of the second closed end 8th can on the pre-formed component 9 made of metallic material supply 15 be generated. These penetrations 14 respectively. 15 are however not absolutely necessary; instead of the penetrations 14 respectively. 15 at the closed end areas 7 respectively. 8th of the highly deformed component 9 external contours that favor a positive fit can also be generated on these.

From the representation according to 4.6 of the figure cycle of the figures 4.1 to 4.6 can be seen that after pivoting the second molded part 16.1 around the axis of rotation 17 in the sense of rotation 19 the pre-formed component by 180 ° 9 after moving back the second molded part 16.2 between the stationary molded parts 16.1 respectively. 16.3 that in the first cavity 18 preformed component 9 now inside the second cavity 20 is positioned. The sections of the first cavity 18 or the second cavity 20 in movable molded part 16.2 of the plate-shaped mold 16 are therefore alternately within the first cavity 18 in the IHU process and within the second cavity 20 used within the injection molding process. After moving back the second movable molded part 16.2 according to the stroke 16.4 can be placed in the first cavity 18 of the plate-shaped configured mold with a pressure medium 6 , such as water, filled blank 1 insert made of metallic material.

This can - as for example in 4.1 and 4.2 shown - by retracting the die 28 with penetrations at both ends and at both ends 14 respectively. 15 be provided.

7 shows a finished hybrid component with plastic and molded head and foot area.

The finished hydroformed component 9 made of metallic material points in a head area 21 and in a foot area 24 Plastic injection areas made of plastic material. It is also possible to use the preformed component 9 to inject plastic material only within one area, this depends on the application of the hybrid component to be manufactured. Depending on the position of the injection openings for the second cavity 20 these areas form for the injection of plastic melt to be injected 21 respectively. 24 on the fully formed component 9 made of metallic material. According to the representation 7 an accelerator pedal is shown in the head area 21 a first pair of cams 22 and a second pair of cams 23 are injected. The within the first stamp entry area 11 arranged penetrations 14 are in 7 interspersed with plastic, ie according to the representation 7 not visible anymore. The same applies to those within the second stamp entry area 12 arranged opening 15 which is now also penetrated by injected plastic material and is therefore also no longer visible. By means of the pairs of cams 22 respectively. 23 can that be in 7 Lock the accelerator pedal shown as an example in an accelerator pedal holder. Due to the positive connection of the plastic material in the head area 21 of the hybrid component 27 is a permanent connection between the material components metal and plastic material. The same applies to those in the area 24 of the hybrid component 27 molded accelerator pedal surface 25 , In the lower area, here next to the second stamp entry area 12 is arranged 7 an emptying opening 26 to see through which the inside of the hybrid component 27 enclosed media 6 can be emptied. The emptying of the pressure medium 6 from the inside of the hybrid component 27 can either be outside the mold 16 take place or between the inside of the mold 16 expiring IHU or Hydro-forming process in the first cavity 18 before the mold 16 reoriented with respect to the injection molding process, ie pivoted or twisted. Between these two process steps there is also an emptying of the pressure medium 6 from the cavity 3 of the hybrid component 27 possible. This can be done by draining the water supply due to the action of gravity as well as by suctioning off the pressure medium 6 from the cavity 3 of the hybrid component 27 respectively.

As long as the drain opening 26 on the fully molded and molded plastic areas 21 respectively. 24 provided hybrid component 27 remains closed, the print medium remains 6 inside the cavity 3 of the hybrid component 27 , so that when the molded component is filled 9 Made of metallic material, ideal conditions for injection molding within the second cavity 20 of the mold 16 given are. By maintaining the filling of the cavity 3 with pressure medium 6 on the hybrid component 27 The elaborate and cost-intensive water treatment is eliminated, since dirt, greases and oils can be kept away from the pressure medium, since this is in the cavity 3 of the hybrid component 27 is completely encapsulated.

In addition to the in 7 exemplary accelerator pedal shown as a hybrid component 1 27 Other vehicle components such as B. produce the front-end component, a bumper system, roof stiffeners and instrument panel supports as hybrid components using the method proposed by the invention.

5 shows a hydroformed metallic component with a laterally arranged recess according to a first connection variant, which can be produced by means of the method proposed according to the invention.

The vertical axis of a hydroformed metal part 30 is designated with Z, the longitudinal axis with the letter Y and the transverse axis with the letter X. Parallel to the Y axis of the hydroformed metallic component 30 stretches a recess produced by means of the hydroforming process 33 , The recess 33 is an indentation on the outside of the profiled metallic molded part 30 arranged. The recess 33 extends over a length 35 on the hydroformed metallic component 30 , The recess formed as an indentation 33 has a first width on the outside of the hydroformed metallic molded part 34 on. The recess 33 is a trained indentation on the hydroformed metal part 30 is preferred, for example, in such a cavity 32 enclosing components generated that have a softer or thinner component.

6 shows in the hydroformed metallic component according to 5 injected plastic material according to the first connection variant.

From the representation according to 6 shows that in the recess 33 that extend along a longitudinal extension 35 in the hydroformed metal part 30 which has a cavity 32 encloses, extends, a plastic material 36 is injected. For this purpose, the hydroformed metallic molded part 30 in a corresponding to the metallic molded part 30 configured mold 16 be inserted, which after inserting the hydroformed metallic molding 30 is closed. The plastic material is injected using a spray head 36 into the recess formed as an indentation 33 on one side of the hydroformed metal part 30 , Due to the injection pressure of the plastic material 36 expands the plastic material present as a plastic melt 36 the recess formed as an indentation 33 on. The recess is widened 33 from the first expanse 34 to a second width, as shown in 6 with reference numerals 38 is designated. Due to the expansion, an undercut is created 37 one so the plastic material 36 and a rib that can be formed on them 40 firmly and permanently in the recess designed as an indentation 33 which are parallel to the Y axis of the hydroformed molded part 31 extends from metallic material, takes place. The firm anchoring of the plastic material 36 , which in the recess procured as an indentation 33 on the outside of the hydroformed metal part 30 penetrates, can be caused by a material accumulation 39 on the outside of the hydroformed metal part 30 get supported. Due to the material accumulation 39 on the outside of the recess provided as an indentation 33 on the hydroformed metal part 30 and that inside the recess 33 trained undercut 37 by widening the recess 33 there is a play-free connection between the plastic material 36 and the rib formed by this 40 and the hydroformed metallic molding 30 which - as in 6 shown - can be designed in the form of a square tube. In addition to the in 6 represented geometry 31 of the hydroformed metallic component 30 other geometries are of course also conceivable.

8th shows a plastic component with an undeformed component made of metallic material inserted into its cavity according to a second connection variant, which can be produced using the method proposed according to the invention.

From the representation according to 8th shows that an injection molded component - shown here in half section - is a tubular metallic component 54 encloses. In in 8th shown mounting condition is a radial distance 53 between an inner surface of the jacket 52 of the coat 51 of the injection molded plastic component 50 available. The metal component that can be deformed by applying an internal pressure 54 can be an expansion area 58 have by weakening its wall thickness 56 can be formed. In the undeformed state of the metallic component 54 this has a first diameter 63 on. The outer peripheral surface 57 of the metallic component 54 - shown here as a tubular body in half section - extends continuously and is in in 8th shown state still undeformed.

When a cavity is loaded 55 of the tubular, metallic component 54 can in the manner of a "tailored tube" a partial and localized expansion of the jacket of the tubular metal component 54 can be reached in the radial direction. This is 9 removable.

9 shows the plastic component according to 8th with a component made of metallic material that has been radially expanded by IHU.

That in a softer area 58 its longitudinal extent through the application of an internal high pressure component radially expanded 54 made of metallic material on a diameter 64 widened. Due to the even pressure distribution in the cavity 55 of the component 54 A metallic material material becomes a first transition area at the time of the radially widened area 60 and a second transition area 61 educated. Due to the radial expansion of the peripheral surface 57 of the tubular configured metallic component 54 there is a tight fit 62 between the inner surface of the jacket 52 of the injection molded plastic component 50 the outer peripheral surface 57 of the component 54 made of metallic material. The radial expansion 59 , ie the diameter difference between the first diameter 63 and the second diameter 64 is with reference numerals 59 characterized. The non-positive connection 62 which by the tight fit of the injection molded part formed as a plastic component 50 on the outer circumference 57 of the metallic component 54 is produced depends on the level of deformability of the metallic component 54 and depending on the level of pressure with which the cavity 55 of the metallic component 54 is applied. Ideally, a targeted local expansion in the radial direction is of a first, undeformed diameter 63 to a second expanded diameter 64 supported by that exactly in the expansion area 58 a kind of weakening of the wall thickness 56 of the internal high pressure deformable metallic component 54 is produced.

With the method according to the invention described above, instead of greasing a metallic component to be deformed by the hydroforming or hydroforming, a film can be drawn over the component, the film reducing the friction 10 can be configured in particular as a shrink film. Contamination of the hybrid component 27 grease residues can thus be avoided. Because of the enclosed media 6 in the interior of the hybrid component to be displayed 27 can be applied by hydroforming according to the principle of a hydraulic balance. By applying the hydraulic pressure corresponding to the stamp entry areas 11 respectively. 12 can the finished outer contour of the hybrid component 27 can be set almost arbitrarily. The print medium 6 can inside 3 of the hybrid component 27 also remain enclosed during the injection molding process and thereby helps to cool and accelerate the hardening of the injected plastic melt in the mold 16 at. Alternatively, the pressure medium, which can preferably be water, can also be from the interior prior to the injection molding process 3 of the molded component 9 be removed from metallic material. This is made considerably easier in particular when the molding tool 16 according to the schematic configuration in 4 is carried out in a substantially vertically oriented modified injection molding machine. The method proposed according to the invention ensures that the complete molding tool is used in hydroforming 17 does not come into contact with the pressure medium and in particular a complex and therefore costly water treatment is avoided, since dirt, greases and oils can be kept completely away from the pressure medium used, since this is encapsulated in the mechanically pre-formed component which is closed on both sides 9 remains enclosed from metallic material.

With the method proposed according to the invention can vehicle components such. B. accelerator pedals, front-end components, Bumper systems, Roof stiffeners and instrument panel supports, to give a few examples name, simple and inexpensive produce.

10 shows a perspective top view of a plastic injection molding machine.

In the 10 schematically illustrated plastic injection molding machine ( 65 ) includes a machine bed ( 69 ), on which both a press area ( 67 ) is included as well as other add-on components. With reference number ( 66 ) is a granulate hopper, by means of which the granules of the injection molding machine which have been converted into flowable plastic melt in the course of the injection molding process ( 65 ) are fed. Within the press area ( 67 ) is a clamping unit ( 68 ) which the individual machine plates ( 16 ) against each other in order to ensure that the mold, not shown here, is closed and the flow of flowable plastic melt from the cavities formed in the mold ( 18 respectively. 20 ) to prevent.

1

to deforming component

2

Bautenmantel

3

Bautenhohlraum

4

first open end

5

second open end

6

enclosed pressure medium (H ₂ O)

7

first closed end (pressed)

8th

second closed end (pressed)

9

pre-strained Component made of metallic material

10

friction-reducing foil

11

stamp

11.1

Stamp area 1st half of the stamp

12

second half of stamp (stamp 11 )

12.1

Stamp area 2nd stamp half

13

contour expansion

14

first Penetration (for Plastic material)

15

second Penetration (for Plastic material)

16

mold

16.1

first Molded part (stationary)

16.2

second Molded part (movable)

16.3

third Molding (stationary)

16.4

Stroke second molding 16.2

17

axis of rotation mold

18

first cavity (IHU)

19

rotation Forming tool (e.g. 180 °?)

20

second cavity (Injection)

21

Plastic headboard

22

first cam pair

23

second cam pair

24

Kunststofffußteil

25

pedal area

26

Discharge opening for pressure medium

27

hybrid component

28

punch

28.1

Punch area

29

Boundary surface cavity

29.1

Contour defining surface

30

metallic molding

31

profiling

32

cavity

33

recess (indentation by hydroforming)

Z-axis, Y axis, X axis

34

first wide recess ( 33 )

35

Longitudinal extension recess ( 33 )

36

Plastic material

37

undercut

38

second wide recess ( 33 )

39

Material accumulation outside

40

Plastic material rib

50

Injection molding plastic component

51

coat

52

Inner surface area

53

radial distance

54

metallic component

55

cavity

56

Wall thickness

57

Outer circumferential surface

58

longitudinal extension Expansion area of hydroforming

59

Diameter extension by IHU

60

first transition area

61

second transition area

62

Tight fit on peripheral surface ( 57 )

63

first diameter

64

second Diameter (deformed)

65

injection molding machine

66

granulate hopper

67

Press area

68

closing unit

69

machine bed

Claims (22)

Process for the production of hybrid components ( 27 ) from a preformed component ( 9 ) metallic material and plastic material in a combined IHU injection molding process with the process steps: a) the preformed component ( 9 ) metallic material with a pressure medium ( 6 ) and at its ends ( 7 . 8th ) closed, b) the preformed metallic component ( 9 ) is in a first cavity ( 18 ) a mold ( 16 ; 16.1 . 16.2 . 16.3 ) inserted its contour ( 11 . 12 . 13 ) hydroformed and breakthroughs ( 14 . 15 ) generated for plastic material, c) after the shaping of the metallic component ( 9 ) the molding tool ( 16 . 16.1 . 16.2 . 16.3 ) moved such that the hydroformed component ( 9 ) in a second cavity ( 20 ) is positioned for injection molding, d) through into the second cavity ( 20 ) injected plastic material becomes the hybrid component ( 27 ) generated while simultaneously in the first cavity ( 18 ) with pressure medium ( 6 ) a preformed component ( 9 ) is hydroformed from metallic material. Method according to claim 1, characterized in that the process steps b) and d) clocked carried out become. A method according to claim 1, characterized in that the molding tool ( 16 . 16.1 . 16.2 . 16.3 ) in process step c) about an axis of rotation ( 17 ) is twisted. A method according to claim 3, characterized in that the molding tool ( 16 . 16.1 . 16.2 . 16.3 ) is pivoted by 180 ° around its axis of rotation. A method according to claim 1, characterized in that according to method step b) during the hydroforming, the pressure on the preformed component ( 9 ) is applied from metallic material according to the principle of the hydraulic balance and the contour ( 11 . 12 . 13 ) by retracting the stamp ( 11 . 28 ) is produced. A method according to claim 5, characterized in that the pre-deformed component ( 9 ) made of metallic material after closing the mold ( 16 . 16.1 . 16.2 . 16.3 ) in a first stamp entry area ( 11 ) and / or in a second stamp entry area ( 12 ) or other stamp entry areas. A method according to claim 5, characterized in that on the preformed component ( 9 ) a widened diameter made of metallic material ( 13 ) is produced. A method according to claim 5, characterized in that during process step b) in preformed component ( 9 ) made of metallic material by retracting cutting punches ( 28 . 28.1 ) breakthroughs that enable a positive fit of the plastic material ( 14 . 15 ) be generated. A method according to claim 1, characterized in that as the pressure medium ( 6 ) for filling the preformed components ( 9 ) water made of metallic material is used. A method according to claim 1, characterized in that during step d) the hydroformed component ( 9 ) in the second cavity ( 20 ) of the mold ( 16 . 16.1 . 16.2 . 16.3 ) in injection areas ( 21 . 27 ) for plastic material is partially overmolded with plastic material. A method according to claim 10, characterized in that the injection areas ( 21 . 24 ) for the plastic material and the parts of the hydroformed component ( 9 ) made of metallic material, in which openings ( 14 . 15 ) so that the plastic material on the hydroformed component 9 ) made of metallic material al is achieved. A method according to claim 1, characterized in that after step d) emptying the pressure medium ( 6 ) from the hybrid component ( 27 ) he follows. A method according to claim 1, characterized in that the emptying of the pressure medium ( 6 ) from the cavity ( 3 ) of the hydroformed component at an emptying opening ( 26 ) inside the mold ( 17 ) before carrying out process step d). A method according to claim 13, characterized in that the emptying of the pressure medium ( 6 ) from the preformed component ( 9 ) made of metallic material by suction before performing step d). A method according to claim 1, characterized in that the process steps a) to d) of the hydroforming process or hydroforming process and injection molding on an essentially vertically acting injection molding machine with a mold that is movable relative to this 16 . 16.1 . 16.2 . 16.3 ) be performed. Process for producing a connection between a hydroformed molded part ( 30 ) and plastic material ( 36 ) according to claim 1 with the following method steps: a) one with a recess ( 33 ) provided, metallic molded part ( 30 ) is placed in the mold ( 16 ) inserted, b) the plastic material ( 36 ) is in the recess ( 33 ) of the molding material ( 30 ) injected and expanded, an undercut ( 37 ) educating on. A method according to claim 16, characterized in that depending on the amount of plastic material injected ( 36 ) and injection pressure an expansion of the recess ( 33 ) on the molded part ( 30 ) from a first width ( 34 ) to a second width ( 38 ) he follows. Method for connecting a plastic component ( 50 ) with a component made of metallic material penetrating this ( 54 ) which can be expanded by means of the IHU process with the following process steps: a) the plastic component ( 50 ) is placed in a cavity of a mold ( 17 ) inserted, whereby it is from the expandable metallic component ( 54 ) is enforced, b) local, partial expansion takes place through hydroforming ( 58 . 59 ) of the component ( 54 ) of metallic material with a first diameter ( 63 ) to a second diameter ( 64 ). A method according to claim 18, characterized in that the local, partial expansion ( 59 ) on a softer area of the component ( 54 ) made of metallic material with reduced wall thickness ( 56 ) is made. A method according to claim 19, characterized in that the area expanded in diameter ( 58 ) of the component ( 54 ) made of metallic material through a first transition area ( 60 ) and a second transition area ( 61 ) is limited. Process for the production of hybrid components ( 27 ) from a pre-formed component ( 9 ) metallic material and plastic material in an injection molding process, with the process steps: a) the preformed component ( 9 ) metallic material with a pressure medium ( 6 ) and at its ends ( 7 . 8th ) closed, b) the preformed metallic component ( 9 ) is inside a cavity ( 20 ) in the injection molding process through the into the cavity ( 20 ) injected plastic melt deformed inside high pressure. Method according to claims 1 and 21, characterized in that on the hybrid component ( 27 ) between the preformed component ( 9 ) made of metallic material and the molded plastic areas ( 21 . 24 ) on the preformed component ( 9 ) The metallic edge is contoured from metallic material.