Hybrid structure and manufacturing method

Abstract

The present invention relates to a hybrid structure, comprising: a first component having a base and an upright wall extending from the base, the first component having an interior enclosed between the upright wall and the base; and a thermoplastic second component molded onto the first component, the second component comprising a reinforcing portion for structurally reinforcing the first component, the reinforcing portion extending in a longitudinal direction of the first component and located in the interior of the first component, the thermoplastic second component further comprising a locking portion extending adjacently on at least a portion of an exterior of the first component, wherein the reinforcing portion and the locking portion are integrally formed to interlock the first component in the thermoplastic second component. The present invention also relates to a method for manufacturing such a hybrid structure, and to a vehicle including such a hybrid structure.

Description

[0001] This application is a divisional application of the invention patent application with the application date of April 6, 2018, Chinese application number 201880024115.0 (international application number PCT / IB2018 / 052414), and invention name “Hybrid structure and manufacturing method”, all contents of which are incorporated herein by reference. Technical Field

[0002] The present invention relates to a hybrid structure, in particular to a hybrid reinforcement member for reinforcing a portion of a vehicle body frame. Furthermore, the present invention relates to a method for manufacturing such a hybrid structure. Furthermore, the present invention relates to a vehicle comprising such a hybrid structure. Background Art

[0003] The engineering systems in today's cars are often designed and built to meet conflicting and complex requirements. While mobility is the primary function of a car, achieving it in an energy-efficient manner and ensuring the safety of the occupants are key requirements. As a result, automotive OEMs are actively working to make vehicles lighter without compromising their safety. Meeting these complex requirements often requires solutions that include innovative designs, manufacturing processes, and multi-material systems.

[0004] Hybrid systems or structures combining various different materials are therefore increasingly used throughout the automotive industry, as they are more than once significantly lighter than single-material systems and exhibit very good performance in terms of safety. Furthermore, hybrid structures are known to offer significant cost advantages through component integration and shortened cycle times. Typically, in a metal-plastic or composite-plastic hybrid system, there is a metal or composite structure that runs through the primary load-bearing path and a secondary plastic structure is connected to the metal or composite structure to improve the local stiffness of the component. Typically, hybrid systems help to reduce weight by up to 50% compared to single-material systems while maintaining the desired performance.

[0005] For example, U.S. Patent Publication No. US2008 / 0138586 discloses interlocking a profile member with a reinforcement member by forcing a polymer material into a wall edge or an opening between two wall edges. The wall edges act as flow guides and runners, carrying the melt throughout the profile member. During the injection molding process, the plastic fills the channels, forming a mechanical interlocking connection between the two materials, forming a hybrid structure.

[0006] The use of dissimilar materials in one system requires a bond between the two dissimilar materials, which in itself is a challenge to overcome. Several bonding techniques have been employed, such as mechanical joining between the metal and secondary structure of the composite structure, or chemical and / or laser treatment of the metal or composite structure before molding the secondary plastic structure onto its surface. The use of adhesives is another method used throughout the industry to improve the bond between dissimilar materials.

[0007] In view of the foregoing, it would be desirable to provide a hybrid assembly having connections between dissimilar materials that alleviates at least some of the perceived inconveniences of the prior art. Summary of the invention

[0008] According to the present invention, a hybrid structure is provided, comprising: a first component having a base and an upright wall extending from the base, the first component having an interior enclosed between the upright wall and the base; and a thermoplastic second component molded to the first component, the second component comprising a reinforcing portion for structurally reinforcing the first component, the reinforcing portion extending in a longitudinal direction of the first component and being located in the interior of the first component, the thermoplastic second component also comprising a locking portion extending adjacently on at least a portion of the exterior of the first component, wherein the reinforcing portion and the locking portion are integrally formed to interlock the first component in the thermoplastic second component.

[0009] It is a challenge to create a connection between two components of different materials that can withstand the mechanical performance requirements of the automotive industry or any other industry where safety is important. The hybrid structure as described herein provides a cost-effective solution for connecting different materials by creating a mechanical lock by (partially) encapsulating a preformed first component within a thermoplastic second component.

[0010] The thermoplastic second component is locked to the first component by encapsulating the first component between a reinforcement portion in the first component and a locking portion adjacent to the exterior of the first component and connected to the reinforcement portion. This locking of the first component can be accomplished by full encapsulation, i.e., the first component is completely encapsulated within the second component, or can be partial encapsulation, i.e., portions of the first component are not covered by or free from the second component. By locking the first component within the second component, a mechanical bond is created between the first component and the second component without the use of adhesives. The hybrid structure can form a single unified member with good structural integrity. The hybrid structure allows for complex geometries to be obtained that would otherwise be difficult to achieve using only metal or composite materials.

[0011] According to one embodiment, the first component comprises at least one through hole, and the locking part is connected to the reinforcing part through the through hole.The through hole may be located in the base and / or the upright wall of the first component.

[0012] In order to additionally fix the second component relative to the first component, the first component may be provided with at least one through hole extending from the outside of the first component to the inside of the first component. The locking portion of the second component extends above and in the through hole. The part of the locking portion extending in the through hole may be connected to or integrally formed with the reinforcement portion of the second component.

[0013] The first component may have at least two opposing upright walls extending from the base so that the interior of the first component forms a channel. The reinforcing portion may then be located in the channel. The reinforcing portion may extend between opposite sides of the channel.

[0014] The reinforcing portion may extend toward the base of the first component and may be adjacent to the base of the first component, thereby filling the space surrounded by the base and the upright walls of the first component. Preferably, the reinforcing portion includes an open structure, such as an alveolar structure including a channel pointing to the base transverse to the first component. The hybrid structure may have a alveolar structure (e.g., an array of columns and channels) more commonly referred to as a "honeycomb". The comb-like body of the structure can be any polygonal or circular shape, such as a circular, oval, square, rectangular, triangular, rhombus, pentagonal, hexagonal, heptagonal and octagonal geometric shape, and a combination including at least one of the foregoing geometric shapes. The plastic honeycomb can be manufactured by molding the plastic honeycomb into the first component.

[0015] In the case where the first component has at least two opposing upright walls with end edges, the reinforcing portion may extend from one end edge of the first component to the opposite end edge. Preferably, the locking portion extends from one end edge of the first component to the opposite end edge on the outside of the first component, thereby connecting with the reinforcing portion at the end edge of the first component.

[0016] The locking portion may be formed as a strip-shaped locking member. The locking portion may extend in a strip-shaped form on the exterior of the first component, thereby partially covering the exterior of the first component. Preferably, the strip-locking member may extend from one side of the second component to the opposite side of the second component on the exterior of the first component, thereby partially covering the exterior of the first component. Preferably, two or more strip-locking members extend on the first component, possibly at a distance from each other that is not equal to zero. Preferably, the strip-locking member covers less than 75% (or less than 50%, for example, less than 30%) of the exterior of the first component.

[0017] Alternatively or additionally, when the first component has at least two opposing upright walls having end edges, the locking portion may include a frame molded on the end edge of the first component, which partially covers the exterior of the first component, thereby surrounding and enclosing the end edge of the first component.

[0018] The frame of the locking portion may be formed integrally with the reinforcing portion. Thus, the locking portion may extend as a frame on (a part of) the outside of the first component and / or through a through hole in the first component and / or from one end edge of the first component to the opposite end edge or a combination thereof.

[0019] According to another embodiment, the base and / or the upright wall comprises a corrugation extending outside thereof in the longitudinal direction of the first component. Preferably, the locking portion adjacent to the exterior of the first component extends with the corrugation in the longitudinal direction. The corrugation may be a deepening or a raised portion relative to the base and / or the upright wall of the first component.

[0020] The locking portion may extend continuously or intermittently along a portion of the corrugation. The length of the corrugation may be shorter than or equal to the length of the first component. The corrugation may include a portion branching at an angle different from 0 or 180 degrees to the longitudinal corrugation, thereby forming a corrugation branch. Preferably, the locking portion also extends on or in the corrugation branch.

[0021] The base of the first component may have a plurality of through holes, and the locking portion extends to the outside of the first component. Preferably, the through holes provided in the base are located at or in the corrugations, and for each corrugation branch, at least one through hole is provided, so that the locking portion can be connected to the reinforcing portion at various positions along the corrugations in the first component, thereby strengthening the mechanical interlocking between the first and second components.

[0022] Additionally or alternatively, the base and / or upright wall may include corrugations at the interior of the first component, wherein the second component extends with the corrugations in the longitudinal direction. The corrugations may be deepened or raised portions relative to the base and / or upright wall of the first component.

[0023] When the second component is molded onto the first component, the corrugations inside the first component can form flow guides for the thermoplastic material. This is particularly advantageous when the reinforcement portion has a toothed structure and the flow guides can guide the thermoplastic material into the mold for the toothed structure in a relatively faster and more efficient manner.

[0024] The base of the first component may have an offset portion, i.e. a corrugation, which forms a deepening outside the first component and a convex portion inside the first component, or a convex portion outside the first component and a deepening inside the first component. Preferably, the corrugation in the base inside the first component is the negative of the corrugation outside the base of the first component.

[0025] Alternatively or additionally, corrugations are provided in the upright walls of the first component, the corrugations extending in the longitudinal direction of the first component. Such corrugations will provide additional strength to the first component.

[0026] According to further embodiments, the first component can be a composite component, a metal component or a composite / metal hybrid component. In addition, the first component can be made of a thermosetting material or a thermoplastic material, wherein the thermoplastic material of the first component has a higher thermal stability and / or a higher flow temperature than the thermoplastic material of the second component.

[0027] Some possible metal component materials include aluminum, titanium, chromium, magnesium, zinc and steel, and a combination or alloy comprising at least one of the foregoing materials. The thickness of the wall of the metal component can be continuous for all walls, or can vary along the first component to enhance the stiffness in the desired direction. For example, one of the opposing walls can have a greater / smaller thickness than another opposing wall. In some embodiments, the wall thickness of the metal component is less than or equal to 1.6 millimeters (mm), specifically, 1.0 mm to 1.5 mm, more specifically 1.3 mm to 1.4 mm. Typically, for an all-metal structure, the wall of the metal component has a wall thickness greater than 1.8 mm. Therefore, the use of plastic reinforcements can reduce the wall thickness by greater than or equal to 10%, specifically, greater than or equal to 20%, and even greater than or equal to 25%.

[0028] Possible composite materials are combinations of plastic matrix materials (being thermoplastic materials or thermosetting materials) and reinforcing filling materials. Examples of such filling materials can be fibers, long fibers or continuous fibers, nonwoven or woven fabrics of continuous fibers. Composite materials can contain at least one of glass, carbon and aramid fibers, respectively. Other possibilities are less commonly used metal fibers, such as boron-tungsten fibers and silicon carbide coated fibers, or ceramic fibers, such as quartz, silicon dioxide or alumina fibers. Examples of thermosetting materials can be polyester resins, polyurethanes, epoxy resins, polyimides or silicone resins, etc.

[0029] Possible thermoplastic materials include polybutylene terephthalate (PBT); acrylonitrile-butadiene-styrene (ABS); polycarbonate; polycarbonate / PET blends; polycarbonate / ABS blends; copolycarbonate-polyester; acrylic-styrene-acrylonitrile (ASA); acrylonitrile-(ethylene-polypropylene diamine-modified)-styrene (AES); phenylene ether resins; polyphenylene ether / polyamide blends; polyamide; polyphenylene sulfide resins; polyvinyl chloride PVC; high impact polystyrene (HIPS); low / high density polyethylene (L / HDPE); polypropylene (PP); expanded polypropylene (EPP); and thermoplastic olefins (TPO). For example, the thermoplastic second component may include Xenoy TM resin, which is commercially available from SABIC. The plastic may optionally be reinforced, for example, with fibers, particles, flakes, and combinations comprising at least one of the foregoing. For example, the thermoplastic second component may be made of STAMAX TMThe thermoplastic second component may also be made of a combination comprising at least one of any of the above materials and / or reinforcements.

[0030] In addition, the characteristics of the second component will depend on the energy absorption characteristics required in a specific area, such as the number of combs per unit area, the thickness of the comb wall and the specific material of the reinforcement. The density of the combs (the number of combs per unit area) depends on the desired stiffness and the material used. In some embodiments, the density can be per 100 square millimeters (mm 2 ) 1 to 20 combs, specifically, every 100 mm 2 1 to 10 combs, more specifically, every 100 mm 2 1 to 5 combs. In various embodiments, the thickness of the wall of the reinforcement portion may be 0.5 mm to 10 mm, specifically 2 mm to 5 mm, and more specifically 2.5 mm to 4 mm.

[0031] The length of the second component can be comparable to or less than the length of the first component (e.g., can be positioned; i.e., only provided at a specific location to obtain enhanced structural integrity at that location). Ideally, to maximize weight reduction, the second component is positioned so as to add the minimum weight required to obtain the desired structural integrity (e.g., greater than or equal to the structural integrity of a standard metal component without the thinner walls). In various embodiments, the length of the second component can be less than or equal to 80% of the length of the first component, specifically, less than or equal to 60%, more specifically, less than or equal to 50%, and more specifically, 10% to 35% of the length of the first component.

[0032] Preferably, the hybrid structure is a reinforcement member for a vehicle body frame. To enable the hybrid structure to be connected to the vehicle body frame as a stiffening or reinforcing component, the exterior of the first component may include a connection area without the second component so that the hybrid structure can be connected to the vehicle body frame. In this way, the hybrid structure can remain unmolded at selective locations, which are further used to connect the member to the body frame. Preferably, the hybrid structure can be connected to the vehicle body frame by at least one of mechanical fasteners, welding and adhesives or any similar connection method.

[0033] The present invention also relates to a vehicle including a hybrid structure as described above. The hybrid structure can be configured to stiffen a portion of a vehicle body frame, such as a body-in-white frame for a motor vehicle (e.g., an automobile). In addition, the hybrid structure can be a reinforcing member for or a portion of one of the A-pillar, B-pillar, C-pillar, D-pillar region, and roof pillars of the vehicle body frame. Alternatively, the hybrid structure can be used to form a full body-in-white or structural body frame of a vehicle. Other applications of the hybrid structure in a vehicle can be used for tailgates, seat frames, bumper beams or other energy absorbing components, front end modules, battery brackets, vehicle cross beams, and any other structural vehicle components for which the hybrid structure as described herein would be beneficial and / or suitable.

[0034] Various weight reduction opportunities are available using hybrid structures by replacing existing metal reinforcements of the body-in-white frame or by replacing complete subsystems such as B-pillars. For example, a combination of high-heat unfilled thermoplastic resins (toughness and ductility) or fiber-reinforced thermoplastic resins (high stiffness and strength) with metals is appropriately selected as needed. For example, an unfilled thermoplastic resin overmolded with multiple metal inserts can be used to replace existing energy absorbing members in floor rockers for side impacts, and a fiber composite thermoplastic resin overmolded with metal inserts is selected to replace an existing B-pillar with comparable crash performance. A hybrid structure designed as a B-pillar can replace a multi-piece B-pillar made of high-strength steel. Metal inserts or components in a hybrid structure can be used for ease of assembly in a body-in-white structure. This solution not only provides the possibility of component integration with the same crash performance as a general-purpose vehicle, but also opens the door to replacing the high-strength steel used today in the body-in-white frame with medium-strength steel, thereby reducing manufacturing costs.

[0035] According to one embodiment, the hybrid structure forms part of a structural body frame. Thus, the first component may be a hollow structural vehicle component of the structural body frame of the vehicle. Preferably, the hybrid structure forms at least a portion of one of the A-pillar, B-pillar, C-pillar, D-pillar region and roof pillar of a body-in-white frame of the vehicle.

[0036] The present invention also relates to a method for manufacturing the above-mentioned hybrid structure, which comprises: providing a first component; providing a thermoplastic second component to the first component by molding a reinforcing portion inside the first component, and molding a locking portion on the outside of the first component to cover at least a portion of the outside, wherein the reinforcing portion and the locking portion are integrally molded so that the second component and the first component are interlocked.

[0037] For this method, a tool or mold or casting having a cavity and a core can be used. The first component can be disposed in the cavity, and the core is inserted into the interior of the first component. The cavity and the core can be shaped to allow the thermoplastic material to flow inside the first component to form the reinforcement portion and flow on the outside of the first component to form the locking portion. Thus, the first component is overmolded with the thermoplastic material to form a thermoplastic second component.

[0038] This can be accomplished by insert molding the thermoplastic material into an injection molding tool, allowing the flowable (molten) thermoplastic material to flow around the first component and solidifying the thermoplastic material to form the second component and form a physical bond between the first component and the second component. Overmolding and / or insert molding can include one of injection molding or injection compression molding.

[0039] According to one embodiment of the method, the base and / or the upright wall of the first component has at least one through hole, and the method further comprises molding the second component through the through hole to form a reinforcement portion or a locking portion.

[0040] Through holes can be provided in the base and / or upright wall and allow the thermoplastic material to flow between the interior and exterior of the first component. When the thermoplastic material solidifies, the material in the through holes connects the reinforcement part inside the first component and the locking part outside the first component.

[0041] Alternatively or additionally, the first component may have at least two opposing upright walls having end edges, the method further comprising molding a reinforcing portion into the interior from one end edge of the first component to an opposite end edge, and molding a locking portion on the exterior of the first component from one end edge of the first component to an opposite end edge, thereby connecting the locking portion to the reinforcing portion at the end edge of the first component.

[0042] Where the first component has at least two opposing upstanding walls having end edges, the method may alternatively or additionally include molding a frame over the end edges of the first component to partially cover the exterior of the first component, thereby surrounding and enclosing the end edges of the first component. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The features and advantages of the present invention will be further understood with reference to the following drawings of several exemplary embodiments, in which:

[0044] Figures 1A-1C A hybrid structure according to an embodiment of the present invention is shown in various views;

[0045] Figure 2A-2C Shows Figures 1A-1C Individual components of a hybrid structure;

[0046] Figure 3A and 3B shows a hybrid structure according to a second embodiment of the present invention;

[0047] Figure 4A and 4B shows a hybrid structure according to a third embodiment of the present invention;

[0048] Figure 5 Shows Figure 3A , 3B and Figure 4A , 4B A top view of an exterior of a first component of a hybrid structure;

[0049] Figure 6 Shows Figure 3A , 3B and Figure 4A , 4B A bottom view of the interior of the hybrid structure;

[0050] Figures 7A-7C shows a hybrid structure according to a fourth embodiment of the present invention; and

[0051] Figure 8 A portion of the structural body frame of an automobile is shown. DETAILED DESCRIPTION

[0052] Figure 1A A top view of an embodiment of a hybrid structure 100 according to the present invention is shown. The hybrid structure 100 includes a first component 110 and a thermoplastic second component 120. The first component has a base 111 and two opposing upright walls 112 extending from the base 111 (see also Figure 2C The base 111 has a plurality of through holes 113 (see Figure 2C ). The upright wall 112 has a plurality of further through holes 116 which are aligned with the through holes 113 of the base 111. The first component has an interior 114 formed as a channel.

[0053] The second component 120 is made of a thermoplastic material molded to the first component 110. The second component 120 has a reinforcement portion 121, which structurally reinforces the first component 120. The reinforcement portion 121 is located in the interior of the channel shape and extends in the longitudinal direction of the channel and between the opposite walls 112 of the first component 110. The thermoplastic second component 120 also includes a locking portion 124, which is adjacent to the exterior 115 of the first component 110. The locking portion 124 includes a band lock 125, which extends adjacently on a portion of the exterior 115 of the first component 110, i.e., covers a portion of the exterior 115 of the first component 110. The band lock 115 is connected to the reinforcement portion 121 through a through hole 113 at the base 111 and another through hole 116 at the upright wall 112 of the first component 110. By extending in the through holes 113, 116 and on the exterior 115, the second component 120 is thus interlocked with the first component 110. The locking portion 124 also includes a frame 126 that is molded onto the end edge 117 of the first component 110, see Figure 1C and 2A The frame 126 encloses the end edge 117 of the first component 110 at the upright wall 112 and at each free end of the first component. The frame 126 is adjacent to a portion of the exterior 115 of the first component 110. The strap lock 125 is connected to the frame 126 at the upright wall 112 at the end edge 117 of the first component 110, thereby forming an integrally formed second component 120 molded onto the first component 110.

[0054] The reinforcement portion 121 is formed into an open alveolar structure. Figure 1B The honeycomb structure forms channels 122, which have an axial direction toward the base 111 of the first component 110. For the embodiment shown in the drawings, the channels 122 of the honeycomb structure are perpendicular to the longitudinal direction of the first component 110. Alternatively, the axial direction of the honeycomb channel can enclose an angle greater than 0 degrees and less than 90 degrees or greater than 90 degrees and less than 180 degrees with the longitudinal direction of the first component 110 or its base 111. Figure 2B The honeycomb walls 123 are shown extending from the base 111 to the end edge 101 of the hybrid structure 100, thus extending over the height of the hybrid structure. Alternatively, the honeycomb walls 123 may extend from the base 111 to the end edge 117 of the first component 110.

[0055] Figure 3A and 3B A hybrid structure 200 according to a second embodiment of the present invention is shown. The hybrid structure 200 includes a first component 210 and a thermoplastic second component 220. The first component has a base 211 and two opposing upright walls 212 extending from the base 211. The base 211 has a plurality of through holes (see Figure 5 ). The upright wall 212 has a plurality of additional through holes (see Figure 5 ), which is aligned with the through hole of the base 211. The first component 210 has an interior 214 formed as a channel, such as Figure 2C As shown. At its outer portion 215, the base 211 of the first component 210 is provided with corrugations which are formed as deepenings 218. At its inner portion 214, the base 211 of the first component 210 is provided with a raised portion (not shown) which is the negative shape of the deepening 218 at the outer portion 215. The deepening 218 is provided with a branch 218a which extends perpendicularly from the deepening 218 in the base 211 towards the end edge 217 of the upright wall 212 of the first component 210, see also Figure 5 The deepening branch 218a has an end at a distance not equal to zero from the end edge 217, ie the branch 218a does not extend to the end edge 217 but ends at a distance not equal to zero from the end edge 217. Alternatively, the branch does end at the end edge.

[0056] The second component 220 is made of a thermoplastic material molded to the first component 210. The second component 220 has a reinforcing portion 221 that structurally reinforces the first component 220. The reinforcing portion 221 is located in the channel and extends in the longitudinal direction of the channel and between the opposite walls 212 of the first component 210. The thermoplastic second component 220 also includes a locking portion 224 that is adjacent to the outer portion 215 of the first component 210 and is disposed in the deepening portion 218 and its branches 218a at the outer portion 215 of the first component 210, thereby forming an intermittent band lock 225 in the deepening portion 218 and its branches 218a. The upper surface of the band lock 225 is flush with the outer portion of the first component 210. The band lock 225 connects the locking portion 224 with the reinforcing portion 221 through a through hole at the base 211 and another through hole at the upright wall 212 of the first component 210. The second component 220 thus interlocks with the first component 210 by extending in the through hole (not shown) and on the outer portion 215. The locking portion 224 also includes a frame 226, which is molded onto the end edge of the first component 210, see Figure 3A The frame 226 encloses the end edge 217 of the first component 210 at the upright wall 212 and at each free end of the first component. The frame 226 is adjacent to a portion of the exterior 215 of the first component 210. The belt lock 225 of this second embodiment of the hybrid structure is not connected to the frame 226.

[0057] Figure 3BThe second component 220 of the hybrid structure 200 is shown, i.e., only the thermoplastic portion of the hybrid structure 200. The second component 220 is formed to partially cover the base 211 inside the first component 210 at the adjacent portion 229, which forms the base portion of the second component 220. The reinforcement portion 221 is formed as an open tooth-groove structure, which is Figure 3B The honeycomb structure forms channels 222 having an axial direction A. In the hybrid structure, the axial direction A points toward the base 211 of the first component 210. For the embodiment shown in the drawings, the channels of the honeycomb structure point perpendicularly to the longitudinal direction of the first component. Figure 3B The adjacent portion 229 is shown to include a honeycomb structure wall 223 extending from the base 211 to the end edge 201 of the hybrid structure 200. Alternatively, the honeycomb structure wall may extend from the base to the end edge of the first component, or extend between the base (and thus not adjacent) and the end edge, and thus not extend completely across the height of the first component or hybrid structure.

[0058] Figure 3B The flow guide 227 is shown, which is shaped according to the raised portion ( Figure 3A ), which is Figure 3A The negative shape of the deepening 218 shown in FIG. Figure 3B The flow guide 227 is formed as a groove extending longitudinally and continuously on the second component 220, and is connected to the frame 226 at each end at the free end of the first component 210.

[0059] Figure 4A and 4B A hybrid structure 300 according to a third embodiment of the present invention is shown. The hybrid structure 300 includes a first component 310 and a thermoplastic second component 320. The first component has a base 311 and two opposing upright walls 312 extending from the base 311. The base 311 has a plurality of through holes (see Figure 5 ). The upright wall 312 has a plurality of additional through holes (see Figure 5 ), which is aligned with the through hole of the base 311. The first component 310 has an interior 314 formed as a channel. At its exterior 315, the base 311 of the first component 310 is provided with corrugations formed as a deepening 318. At its interior 314, the base 311 of the first component 310 is provided with a raised portion (not shown) which is the negative shape of the deepening 318 at the exterior 315. The deepening 318 is provided with a branch (318a) which extends vertically from the deepening 318 in the base 311 towards the end edge 317 of the upright wall 312 of the first component 310 (see Figure 5The deepening branch 318a has an end at a distance from the end edge 317 that is not equal to zero, ie the branch 318a does not extend to the end edge 317 but ends at a distance from the end edge 317 that is not equal to zero.

[0060] The second component 320 is made of a thermoplastic material molded to the first component 310. The second component 320 has a reinforcement portion 321, which structurally reinforces the first component 320. The reinforcement portion 321 is located inside the first component and extends in the longitudinal direction of the channel and between the opposite walls 312 of the first component 310. The thermoplastic second component 320 also includes a locking portion 324, which is adjacent to the outer portion 315 of the first component 310 and is arranged in the deepening 318 and its branches located at the outer portion 315 of the first component 310, thereby forming an intermittent band lock 325 in the deepening 318. The band lock 325 connects the locking portion 324 with the reinforcement portion 321 through a through hole at the base 311 and another through hole at the upright wall 312 of the first component 310. By extending in the through holes 313, 316 and on the outer portion 315, the second component 320 is thus interlocked with the first component 310. The locking portion 324 also includes a frame 326 that is molded onto the end edge of the first component 310 (see Figure 5 ). The belt lock 325 extends in the lateral direction in the branch and further extends toward the frame 326. Thus, the belt lock 325 of this third embodiment of the hybrid structure is connected to the frame 226. The belt lock 325 has a portion disposed in the branch 318a of the deepening 318 at the upright wall 312, and a second portion covering the outer portion 315 of the first component 310 and connected to the frame 326.

[0061] Figure 4B A second component 320 of the hybrid structure 300 is shown, i.e., only the thermoplastic portion of the hybrid structure 300 is shown in FIG. Figure 4B The second component 320 is formed to completely cover the base 311 of the first component 310 at an adjacent portion 329 forming the base of the second component 320 .

[0062] Figure 5 Shows Figure 3A , 3B and Figure 4A , 4B310 of a hybrid structure. The first component 210, 310 has a base 211, 311 and two opposing upright walls 212, 312 extending from the base 211, 311. The base 211, 311 has a plurality of through holes 213, 313. The upright walls 212, 312 have a plurality of further through holes 216, 316, which are aligned with the through holes 213, 313 of the base 211, 311. At its outer portion 215, 315, the base 211, 311 of the first component 210, 310 is provided with corrugations, formed as deepenings 218, 318. At its inner portion, the base of the first component is provided with a raised portion (not shown) which is the negative shape of the deepening 218, 318 at the outer portion 215, 315. The deepening 218, 318 is provided with a branch 218a, 318a extending vertically from the deepening 218, 318 in the base 211, 311 towards the end edge 217, 317 of the upright wall 212, 312 of the first component 210, 310. The deepening branch 218a, 318a ends at a distance from the end edge 217, 317 that is not equal to zero, i.e. the branch 218a, 318a does not extend to the end edge 217, 317, but ends at a distance from the end edge 217, 317 that is not equal to zero.

[0063] Figure 5 It is also shown that at each free end of the intermittent belt lock 225 , 325 in the deepening, a through hole 213 , 313 , 216 , 316 is provided so that each end of the belt lock 225 , 325 is connected to the reinforcement part 221 , 321 .

[0064] Figure 6 Shows Figure 3A , 3B and Figure 4A , 4B The bottom view of the interior 214, 314 of the hybrid structure 200, 300. The reinforcement portion 221, 321 of the second component 220, 320 is formed in the interior 214, 314 of the first component 210, 310. The reinforcement portion 221, 321 has an open tooth groove structure. Figure 6 The honeycomb structure forms channels 222, 322 having an axial direction A, see also Figure 3B In the hybrid structure 200 , 300 , the axial direction A points to the base 211 , 311 of the first component 210 , 310 . Figure 6 Flow guides 227, 327 are shown, which are shaped according to raised portions 219, 319, which are Figure 5 The negative shape of the deepening 218 , 318 shown in . Figure 6The flow guide 227 in the second assembly 220 , 320 is formed as a groove extending longitudinally and continuously on the second assembly 220 , 320 , connected to the frame 226 , 326 at each end at the free end of the first assembly 210 , 310 .

[0065] Figures 7A-7C A hybrid structure 400 according to a fourth embodiment of the present invention is shown. The hybrid structure 400 comprises a first component 410 and a thermoplastic second component 420, which extends from an upright wall 412 and a base 411 in the longitudinal direction of the first component 410. Thus, the first and second components extend in a parallel manner. The second component 420 comprises a reinforcing portion 421 and another upright wall 428, which delimits the second component 420 and the reinforcing portion 421 in the transverse direction. The reinforcing portion 421 has a honeycomb tooth-groove structure, in which a channel 422 has an axial direction A perpendicular to the base 411 of the first component. The channel 422 is delimited by a cell wall 423.

[0066] The raised portion 419 extends in the longitudinal direction along the base 411 of the first component, see Figure 7B The raised portion 419 has a vertical branch 419a. In the raised portion 419 and its branch 419a, a plurality of through holes 413, 416 are provided, each of which is spaced apart from another through hole by a distance. Fig. 7A The longitudinally extending raised portion 419 is shown covered by the thermoplastic material of the second component 420 .

[0067] Figure 7C A deepening 418 is shown provided at the exterior 415 of the first component 410, which has a vertical branch 418a. The deepening 418 and the vertical deepening branch 418a are the negative shape of the raised portion 419 and the raised portion branch 419a at the interior 414 of the first component 410, or vice versa. The through holes 413, 416 extend from the interior 414 of the first component 410 to the exterior 416, or vice versa. The deepening 418 and its branches contain intermittent locking portions 424 and branched band locks 425 to lock the second component 420 with the first component 410 to form the hybrid structure 400.

[0068] To form the hybrid structure 100, 200, 300, 400, the first component 110, 210, 310, 410 is preformed with a base 111, 211, 311, 411 and one or two upright walls 112, 212, 312, 412. The first component is then inserted into a cavity (not shown) of an injection molding tool or mold or die (not shown) formed to receive the first component 110, 210, 310, 410 and form a portion of the second component 120, 220, 320, 420, specifically the locking portion 124, 224, 324, 424 with or without at least a portion of the frame portion 124, 224, 324, 424. The injection molding tool is then closed by inserting a core into the interior 114, 214, 314, 414 of the first component 110, 210, 310, 410. The core is shaped to form the reinforcement 121, 221, 321, 421, in particular its alveolar or honeycomb structure, and possibly at least a portion of the frame 116, 216, 316. After closing the mold or die, a flowable or molten thermoplastic material is injected into the tool through the injection points. Figures 3A to 7C The raised portions 219, 319, 419 shown in the figure are used as flow guides during the injection of the flowable thermoplastic material so that the material can flow more easily into the core to form the honeycomb unit. When the thermoplastic material is cooled, the second component 120, 220, 320, 420 solidifies to at least partially encapsulate the first component 110, 210, 310, 410, thereby interlocking with each other and forming the hybrid structure 100, 200, 300, 400.

[0069] When the first component 110, 210, 310, 410 is made of a composite material, preforming of the first component 110, 210, 310, 410 may be performed simultaneously with injection molding of the second component 120, 220, 320, 420 in a single machine (this is called an integrated manufacturing cell).

[0070] Figure 8 A portion of a structural body frame 500 of a vehicle, more specifically a portion of a structural body frame of an automobile, is shown. Hybrid structures can be located in various areas of the vehicle, such as in the body-in-white (BIW, also known as the body-in-black), such as in the A-pillar 504, the B-pillar 502, the roof rail 503, and the floor rocker 501, among others, and combinations comprising at least one of the foregoing.

[0071] The structural body frame includes a plurality of hollow vehicle components, such as A-pillars 504, B-pillars 502, roof rails 503, and floor rockers 501, etc., which are welded together or otherwise connected. The hybrid structure 100, 200, 300, 400 can be used as a reinforcement for such hollow vehicle components, which is inserted into the space formed by the hollow components, or as a structural member of the body frame. In the latter case, the first component 110, 210, 310, 410 of the hybrid structure 100, 200, 300, 400 can form a hollow vehicle component, such as A-pillars 504, B-pillars 502, roof rails 503, and floor rockers 501, etc., and the second component 120, 220, 320, 420 is injection molded into the hollow vehicle component for reinforcement.

[0072] Some examples of hybrid structures are described below.

[0073] Aspect 1: A hybrid structure comprising: a first component having a base and upright walls extending from the base (preferably, at least two opposite upright walls extend from the base, preferably extending from the base in the same direction), the first component having an interior encapsulated between the upright walls and the base; and a thermoplastic second component molded to the first component, the second component comprising a reinforcing portion for structurally reinforcing the first component, the reinforcing portion extending in the longitudinal direction of the first component and located in the interior of the first component, the thermoplastic second component also comprising a locking portion extending adjacently on at least a portion of the exterior of the first component, wherein the reinforcing portion and the locking portion are formed integrally so as to interlock the first component in the thermoplastic second component.

[0074] Aspect 2: A hybrid structure, wherein the first component includes a through hole, and the locking portion is connected to the reinforcing portion through the through hole.

[0075] Aspect 3: A hybrid structure according to any one of the preceding aspects, wherein the first component has at least two opposing upright walls with end edges, and the reinforcing portion extends from one end edge of the first component to the opposite end edge, and wherein the locking portion extends from one end edge of the first component to the opposite end edge on the outside of the first component, thereby connecting to the reinforcing portion at the end edge of the first component.

[0076] Aspect 4: A hybrid structure according to any one of the preceding aspects, wherein the first component has at least two opposing upright walls with end edges, wherein the locking portion includes a frame molded on the end edge of the first component and partially covering the outside of the first component, thereby surrounding and encapsulating the end edge of the first component.

[0077] Aspect 5: The hybrid structure according to any of the preceding aspects, wherein the reinforcing portion comprises an alveolar structure comprising channels directed transversely to the base of the first component.

[0078] Aspect 6: A hybrid structure according to any one of the preceding aspects, wherein at the outside of the first component, the base includes corrugations extending in the longitudinal direction of the first component, wherein the locking portion adjacent to the outside of the first component extends along the longitudinal direction with the corrugations.

[0079] Aspect 7: The hybrid structure according to any one of the preceding aspects, wherein at an interior of the first component, the base comprises corrugations, and wherein the second component extends along the corrugations in a longitudinal direction.

[0080] Aspect 8: The hybrid structure according to any one of the preceding aspects, wherein the first component is a composite component, a metal component, or a composite / metal hybrid component.

[0081] Aspect 9: The hybrid structure according to aspect 8, wherein the hybrid structure is a reinforcement member for a body frame of a vehicle, and the reinforcement member can be connected to the body frame by at least one of a mechanical fastener, a weld, and an adhesive.

[0082] Aspect 10: A vehicle comprising the hybrid structure according to any one of the preceding aspects.

[0083] Aspect 11: The vehicle according to Aspect 10 further includes a structural body frame, wherein the hybrid structure forms a portion of the structural body frame, preferably forming at least a portion of one of the A-pillar, B-pillar, C-pillar, D-pillar area and roof pillar of the vehicle's body-in-white frame.

[0084] Aspect 12: A method for manufacturing a hybrid structure according to any one of the preceding aspects, the method comprising: providing the first component; arranging the thermoplastic second component on the first component by molding a reinforcing portion in the interior of the first component and molding the locking portion on the exterior of the first component to cover at least a portion of the exterior, wherein the reinforcing portion and the locking portion are integrally molded so that the second component and the first component are interlocked.

[0085] Aspect 13: The method according to aspect 12, wherein the base and / or the upright wall of the first component has a through hole, and the method further comprises molding the second component through the through hole to form the reinforcement portion or the locking portion.

[0086] Aspect 14: A method according to Aspect 12 or 13, wherein the first component has at least two opposing upright walls with end edges, the method further comprising molding the reinforcing portion into the interior from one end edge of the first component to the opposite end edge, and molding the locking portion on the exterior of the first component from one end edge of the first component to the opposite end edge, thereby connecting the locking portion to the reinforcing portion at the end edge of the first component.

[0087] Aspect 15: A method according to any one of Aspects 12-14, wherein the first component has at least two opposing upright walls with end edges, and the method further includes molding a frame on the end edges of the first component to partially cover the exterior of the first component, thereby surrounding and encapsulating the end edges of the first component.

[0088] Generally, the present invention may alternatively include, consist of or substantially consist of any suitable components disclosed herein. The present invention may be additionally or alternatively formulated to be free of or substantially free of any components, materials, ingredients, adjuvants or substances used in prior art compositions or otherwise not necessary for achieving the functions and / or purposes of the present invention. The endpoints of all ranges for the same component or property are inclusive and independently combinable (e.g., the range of "less than or equal to 25wt%, or 5wt% to 20wt%" includes the endpoints and all intermediate values ​​of the range of "5wt% to 25wt%" etc.). In addition to a wider range, disclosing a narrower range or a more specific group is not a waiver of a wider range or a larger group. "Combination" includes blends, mixtures, alloys, reaction products, etc. In addition, the terms "first", "second", etc. herein do not represent any order, quantity or importance, but are used to indicate an element with another element. The terms "a" and "an" and "the" herein do not represent a limit on quantity, and should be interpreted as covering singular and plural numbers, unless otherwise specified herein or the context is clearly contradictory. Unless otherwise stated, "or" means "and / or". As used herein, the suffix "(s)" is intended to include the singular and plural of the term it modifies. References throughout the specification to "one embodiment" mean that the specific elements (e.g., components, structures and / or features) described in conjunction with the embodiment are included in at least one embodiment described herein and may or may not be present in other embodiments. In addition, it should be understood that the described elements can be combined in any suitable manner in various embodiments. "At least one of A, B or C" is equivalent to "A, B, C and a combination of at least one of the foregoing". That is, there are one or more members of the group. For example, "elliptical, square, rectangular, triangular, rhombus, pentagonal, hexagonal, heptagonal and octagonal geometric shapes, and a combination of at least one of the foregoing geometric shapes" is equivalent to "at least one of the elliptical, square, rectangular, triangular, rhombus, pentagonal, hexagonal, heptagonal or octagonal geometric shapes".

[0089] "Optional" or "optionally" means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event occurs and instances where it does not occur. Unless otherwise defined, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs.

[0090] All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in this application contradicts or conflicts with a term in an incorporated reference, the term in this application takes precedence over the conflicting term in the incorporated reference. This application claims priority to U.S. Provisional Application Serial No. 62 / 483,560, filed April 10, 2017, the entire contents of which are incorporated herein.

[0091] Although specific embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may occur to the applicant or those skilled in the art. Therefore, the appended claims as filed and as they may be amended are intended to include all such alternatives, modifications, variations, improvements, and substantial equivalents.

[0092] Parts List

[0093] 100, 200, 300, 400. Mixed structure

[0094] 101, 201, 301. End edge of mixed structure

[0095] 110, 210, 310, 410. First component

[0096] 111, 211, 311, 411. Base

[0097] 112, 212, 312, 412. Vertical wall

[0098] 113, 213, 313, 413.Through hole

[0099] 114, 214, 314, 414. Interior / channel of the first component

[0100] 115, 215, 315, 415. Exterior of the first component

[0101] 116, 216, 316. Other through holes

[0102] 117, 217, 317. End edge of the first component

[0103] 218, 318, 418. Deepening

[0104] 218a, 318a, 418a. Branches

[0105] 219, 319, 419. Raised part

[0106] 219a, 319a, 419a. Branches

[0107] 120, 220, 320, 420. Second component

[0108] 121, 221, 321, 421. Strengthening part

[0109] 122, 222, 322, 422. Channels of honeycomb structure

[0110] 123, 223, 323, 423. Strengthening the cell wall

[0111] 124, 224, 324, 424. Locking part

[0112] 125, 225, 325, 425. With lock

[0113] 126, 226, 326.Frame

[0114] 227, 327, 427. Flow diversion channel

[0115] 428. Vertical Wall

[0116] 229, 329. Adjacent part / base of second component

[0117] 500. Vehicle body frame

[0118] 501. Floor rocker

[0119] 502.B-column

[0120] 503. Roof rails

[0121] 504.A-column

Claims

1. A hybrid structure comprising: a first component having a base, a first upright wall extending from the base, and a second upright wall extending from the base, the first upright wall being opposite the second upright wall, the first component having an interior enclosed between the first upright wall, the second upright wall, and the base, and a thermoplastic second component molded onto the first component, the thermoplastic second component comprising a reinforcing portion for structurally reinforcing the first component, the reinforcing portion extending in a longitudinal direction of the first component and located in an interior of the first component, the thermoplastic second component further comprising a locking portion extending adjacently on at least a portion of an exterior of the first component, wherein the reinforcing portion and the locking portion are integrally formed to interlock the first component in the thermoplastic second component; Wherein, the locking part includes a plurality of belt locks, which extend adjacently on the outer surface of the base, the outer surface of the first upright wall and the outer surface of the second upright wall, and the belt locks have a first free end on the first upright wall and a second free end on the second upright wall. 2 . The hybrid structure according to claim 1 , wherein the first component includes a through hole, and the locking portion is connected to the reinforcing portion through the through hole.

3. The hybrid structure according to claim 1 or 2, wherein the first upright wall and the second upright wall have end edges, and the reinforcing portion extends from one end edge of the first component to the opposite end edge, and wherein the locking portion extends from the one end edge of the first component to the opposite end edge on the outside of the first component, thereby connecting with the reinforcing portion at the end edge of the first component.

4. A hybrid structure according to claim 1 or 2, wherein the first upright wall and the second upright wall have end edges, wherein the locking portion includes a frame, which is molded on the end edge of the first component and partially covers the outside of the first component, thereby surrounding and enclosing the end edge of the first component.

5. A hybrid structure according to claim 1 or 2, wherein the reinforcing portion comprises a gullet structure comprising channels directed transversely to the base of the first component.

6. The hybrid structure according to claim 1 or 2, wherein the first component is made of a composite material.

7. The hybrid structure according to claim 1 or 2, wherein the first component is a metal component.

8. The hybrid structure according to claim 1 or 2, wherein the first component is a hybrid component made of a composite material and a metal.

9. The hybrid structure of claim 6, wherein the hybrid structure is a reinforcement member for a body frame of a vehicle, and the reinforcement member is connectable to the body frame by at least one of mechanical fasteners, welds, and adhesives.

10. A vehicle comprising the hybrid structure according to any one of claims 1 to 9.

11. The vehicle of claim 10, further comprising a structural body frame, wherein the hybrid structure forms a portion of the structural body frame.

12. The vehicle of claim 11, wherein the hybrid structure forms at least a portion of one of an A-pillar, B-pillar, C-pillar, D-pillar region and a roof pillar of a body-in-white frame of the vehicle.

13. A method for manufacturing a hybrid structure according to any one of claims 1 to 9, the method comprising: providing the first component; The thermoplastic second component is disposed on the first component by molding the reinforcing portion on the interior of the first component and molding the locking portion on the exterior of the first component to cover at least a portion of the exterior, wherein the reinforcing portion and the locking portion are integrally molded so that the thermoplastic second component and the first component are interlocked.

14. The method of claim 13, wherein the base and / or the upright wall of the first component has a through hole, and the method further comprises molding the thermoplastic second component through the through hole to form the reinforcement portion or the locking portion.

15. A method according to claim 13 or 14, wherein the first upright wall and the second upright wall have end edges, and the method also includes molding the reinforcement portion into the interior from one end edge of the first component to the opposite end edge, and molding the locking portion on the exterior of the first component from the one end edge of the first component to the opposite end edge, thereby connecting the locking portion to the reinforcement portion at the end edge of the first component.

16. The method of claim 13 or 14, wherein the first upright wall and the second upright wall have end edges, the method further comprising molding a frame on the end edges of the first component to partially cover the exterior of the first component, thereby surrounding and encapsulating the end edges of the first component.

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