Method for producing a semi-finished product or component comprising a metal carrier and a hardenable coating with fiber-reinforced plastic

Patent metadata

Field	Value
Publication number	US-9566745-B2
Application number	US-201314391813-A
Country	US
Kind code	B2
Filing date	Apr 15, 2013
Priority date	Apr 13, 2012
Publication date	Feb 14, 2017
Grant date	Feb 14, 2017

Abstract

The invention relates to a method for producing a semi-finished product or component ( 2 ), in which a hardenable coating ( 6, 17 ) with fiber-reinforced plastic is applied to a metal carrier ( 3 ), particularly a metal sheet ( 4 ), and the coated metal carrier ( 3 ) is formed, particularly deep-drawn or bent, in a subsequent step to produce a semi-finished product or component ( 2 ). According to the invention, for an improved and cost-effective method, the metal carrier ( 3 ) is coated at most only in certain regions and is only subjected to the forming when the coating thereof ( 6, 17 ) has hardened to produce at least a block-resistant surface ( 12 ), the coated metal carrier ( 3 ) being formed such that the plastic changes in shape follow forming radii ( 21 ) and are produced substantially, preferably exclusively, in the coating-free regions ( 15 ) of the metal carrier.

First claim

The invention claimed is:

1. Method for the production of a semi-finished product or component, the method comprising steps of:
applying a hardenable coating with fiber-reinforced plastic to a metal support, the hardenable coating being applied to certain regions of the metal support and other regions of the metal support being left free as coating-free regions,
hardening the hardenable coating on the metal support such that the hardenable coating forms a block-resistant surface, and
forming the coated metal support with the block-resistant surface such that the metal support undergoes plastic deformation along forming radii, the forming radii being exclusively in the coating-free regions of the metal support.

2. Method according to claim 1 , wherein carbon-fiber-reinforced plastic is applied to the metal support with a duroplastic matrix as the fiber-reinforced plastic.

3. Method according to claim 2 , wherein pre-impregnated carbon fibers are applied.

4. Method according to claim 1 , wherein fiber-reinforced plastic is applied to the metal support with a chemically cross-linked intermediate layer.

5. Method according to claim 1 , wherein the fiber-reinforced plastic has long fibers.

6. Method according to claim 1 , wherein a woven fabric or laid scrim of the fiber-reinforced plastic is applied to the metal support in cut-to-size form.

7. Method according to claim 6 , wherein the woven fabric or the laid scrim is either applied to the metal support pre-impregnated with the plastic matrix, or impregnated with the plastic matrix after application to the metal support.

8. Method according to claim 1 , further comprising a step of metallically and/or organically pre-coating the metal support before applying the hardenable coating.

9. Method according to claim 8 , wherein an adhesion-promoting agent is used to metallically and/or organically pre-coat the metal support.

10. Method according to claim 1 , wherein multiple plies of woven fabric or laid scrim are laid one on top of the other for a multidirectional layer structure of the fiber-reinforced plastic.

11. Method according to claim 1 , wherein a parting layer is applied to the coating before forming.

12. Method according to claim 1 , wherein the metal support is a sheet having a sheet thickness of 0.6 to 5 mm.

13. Method according to claim 1 , wherein the hardenable coating has a thickness of 0.2 to 3 mm.

14. Method according to claim 1 , wherein the hardenable coating is pre-gelled without pressure and is pressed onto the metal support in a further step, in order to apply it to the metal support.

15. Method according to claim 1 , further comprising a step of:
producing a supporting structural component from the formed coated metal support.

16. Method according to claim 15 , wherein the supporting structural component is selected from the group consisting of a rocker panel of a motor vehicle and a side member of a motor vehicle.

17. Method according to claim 1 , wherein the metal support is sheet metal.

18. Method according to claim 1 , wherein the forming step comprises deep-drawing or bending of the coated metal support with the block-resistant surface.

19. Method according to claim 1 , wherein the metal support is a sheet having a sheet thickness of 1 to 2.5 mm.

20. Method according to claim 1 , wherein the hardenable coating has a thickness of 0.4 to 2 mm.

Assignees

• Voestalpine Stahl Gmbh

Inventors

• Androsch Franz
• Eyssell Carola
• Strauss Bernhard
• Walch Christian

Classifications

• B29L2031/3002

  Superstructures characterized by combining metal and plastics, i.e. hybrid parts · CPC title

• B29C66/7212

  characterised by the composition of the fibres · CPC title

• B29C66/73751

  the to-be-joined area of at least one of the parts to be joined being uncured, i.e. non cross-linked, non vulcanized · CPC title

• B05D3/12

  by mechanical means · CPC title

• B29C66/472

  said single elements being substantially flat · CPC title