Method for producing metal structural component provided with composite reinforcement

Abstract

A method for manufacturing a metal structural component provided with a composite reinforcement comprises the steps of providing a batch or slab (9) made of a composite material, preparing a structural element (12) made of a metal material of a vehicle, arranging the batch or slab (9) on a portion of the structural element (12), and forming a metal reinforcement on the structural element (12). And applying pressure to the batch or slab (9) such that the batch or slab deforms itself when pressed against the portion of the structural element (12) until the batch or slab covers at least a portion of the contour of the portion of the structural element (12).

Description

Technical Field

[0001] This invention generally relates to the automotive field; more specifically, it relates to a method for manufacturing a metal structural component having a composite reinforcement, and a metal structural component having a composite reinforcement. Summary of the Invention

[0002] Hybrid structures designed for use in the automotive field are known, such as suspension arms made of composite materials. These hybrid structures contain metal reinforcements (typically connecting parts, such as pins, bolts, or bushings) and are incorporated into the composite matrix through co-molding or overmolding.

[0003] The document WO 2022049558 A1 discloses an example of such a solution.

[0004] Using this technology, it is possible to produce articles whose structure has significant composite material properties, locally reinforced by adding or partially embedding metal inserts.

[0005] However, composite components manufactured in this way may not always provide the same mechanical properties as equivalent structural elements traditionally made of metal (such as suspension components in motor vehicles, such as beams or steering knuckles). Furthermore, when production lines are already established to manufacture such metal parts, it is difficult to replace them with composite components because such a replacement would require a complete overhaul of the production system.

[0006] In contrast to existing technologies in which structural composite elements include reinforcing metal inserts, the present invention proposes a solution for vehicle structural components (e.g., suspension elements) made of metal with reinforcing regions made of composite materials.

[0007] According to a preferred embodiment, the object of the present invention is to provide a novel hybrid metal-composite suspension steering knuckle, which, unlike conventional composite structures that use multiple metal inserts, has a metal steering knuckle that is locally reinforced at one or more of its auxiliary arms by the assistance and application of appropriately reinforced composite materials.

[0008] To achieve this, according to the invention, metal structural elements (e.g., lateral members or suspension steering knuckles) are used as corresponding molds for manufacturing composite reinforcing elements.

[0009] This can be achieved by applying patches or reinforcements to metal components using an intercalated structural adhesive or viscoelastic medium suitable for bonding the metal and composite components together, or, in the absence of an intercalated adhesive medium, by identifying the resin constituting the composite material as the medium for ensuring the bonding of these components. This solution allows for the simultaneous construction of reinforcing elements made of composite materials and the activation of the adhesive polymerization and consolidation processes.

[0010] According to one embodiment, a sheet made of carbon fiber or glass fiber reinforced composite material is applied to a metal structural element via a sheet material compression molding process (SMC or "sheet molding compound", PMC or "prepreg molding compound" material, wherein the fibers are impregnated with a thermosetting resin, such as epoxy resin or vinyl ester resin).

[0011] According to one embodiment, a multilayer composite material is provided, wherein the slab of the material is prepared in such a way that a structural adhesive (e.g., paste or tape) layer is present on the first layer (i.e., on the surface of the slab intended to contact the metal component).

[0012] Composite material can be deposited in a half-mold, the shape of which is complementary to the contour of a metal blank (e.g., a suspension steering knuckle to be locally reinforced), which is arranged to act as a corresponding mold for the composite material. The material is then arranged to directly contact the outer surface of the structural element, and pressure is applied after mold closing to bond and adhere the reinforcing plate to the metal element. The bonding method can be such that the reinforcing plate completely covers the corresponding portion of the metal element to be reinforced (thus, a single reinforcing element can be directly adhered to the reinforcing surface without having to split it into two conformal shells to replicate the surface of the element to be reinforced).

[0013] In an alternative embodiment, the reinforcing plate is directly disposed on the metal structural element, and the resulting assembly is placed in a vacuum bag that ensures the elimination of any residual air present between any layers of the plate. The assembly is then placed in an autoclave and vacuum-loaded by applying pressure and temperature, thereby compacting the composite reinforcement and adhering it to the metal structural element.

[0014] A further difference between a solution according to the present invention and the prior art is that, instead of preforming the composite panel, the panel is formed simultaneously with the bonding of the metal structural elements.

[0015] According to one aspect of the invention, the above and other objects and advantages are achieved by a method for manufacturing a metal structural component provided with a composite reinforcement and a metal structural component provided with a composite reinforcement, said method and component having the features defined in the appended claims. Attached Figure Description

[0016] The functional and structural features of some preferred embodiments of a solution according to the present invention will now be described. The description will be made with reference to the accompanying drawings, in which:

[0017] - Figure 1 and Figure 2 These are two schematic perspective views of a reinforcing structural element according to one embodiment of the present invention, showing a metal blank structural element and an identical metal structural element provided with a reinforcement made of composite material; and

[0018] - Figures 3 to 10 This is a schematic diagram of the corresponding steps of a method for applying a reinforcement made of composite material to a metal structural element according to an embodiment of the present invention. Detailed Implementation

[0019] Before detailing various embodiments of the invention, it should be understood that the application of the invention is not limited to the design details and configurations of the components presented in the following description or shown in the drawings. Other embodiments of the invention may exist, and it may be implemented or constructed in different ways in practice. It should also be understood that the wording and terminology used herein are intended for descriptive purposes and should not be construed as limiting.

[0020] For reference by example Figure 1 and Figure 2 The reinforcing structural element according to the invention comprises: a structural element 12 of a vehicle made of metallic material (in the illustrated example, a suspension steering knuckle), on which a reinforcing plate 15 made of composite material is applied to a portion of the structural element (an arm or accessory arm of the suspension steering knuckle adapted to connect the steering knuckle to other elements of the suspension system).

[0021] According to one aspect of the invention, a method for manufacturing a metal structural component provided with a composite reinforcement includes the following steps: providing a batch or blank 9 made of a composite material; providing a structural element 12 made of a metallic material of a vehicle; arranging the batch or blank 9 on a portion of the structural element 12; and applying pressure to the batch or blank 9 such that the batch or blank deforms itself upon pressing against the portion of the structural element 12 until the batch or blank covers at least a portion of the contour of the portion of the structural element 12. These steps are... Figures 3 to 6 The sequence is schematically visible.

[0022] According to a preferred embodiment, structural element 12 is an automotive suspension component, such as a crossbeam or a suspension steering knuckle.

[0023] The suspension steering knuckle can be made of aluminum, for example, using processes such as forging or die casting. Then, the area on the cast billet where the composite reinforcement will be applied can be sandblasted.

[0024] Preferably, the portion of the structural element 12 containing the composite batch or slab 9 is the arm of the suspension steering knuckle.

[0025] According to one embodiment, when the batch or slab 9 covers this portion of the structural element 12, a step of applying pressure to the batch or slab is performed, ensuring that said portion of the structural element 12 is covered with composite material only from one side, where the single batch or slab 9 was initially laid. In other words, the structural element 12 is coated only from one side, such that the coating consists of a single composite reinforcing plate (15), rather than two opposing plates. According to this embodiment, the coating can then be closed around that portion of the structural element 12 to seamlessly surround the entire periphery or contour of that portion.

[0026] According to an alternative embodiment, the provided steps include: preparing two batches or blanks 9 of the composite material, and laying the batches or blanks 9 on opposite sides of the portion of the structural element 12 such that, by performing a compression step of the batches or blanks 9, the portion of the structural element 12 is covered with the composite material starting from its two opposite sides. According to this embodiment, the coating can then be closed around the portion of the structural element 12 to seamlessly surround the entire periphery or contour of the portion.

[0027] According to an implementation plan, such as through Figures 7 to 10 As shown in the example, the step of applying pressure to the batch or blank 9 to cover the portion of the structural element 12 includes the following sub-steps: preparing a mold 14, which includes two half molds that together define a cavity suitable for receiving the batch or blank 9 and at least the portion of the structural element 12;

[0028] Insert the batch material or blank 9 into the cavity of one half of the mold and insert the portion of the structural element 12 into the cavity of the other half of the mold, such that the batch material or blank 9 faces the portion of the structural element 12; and close the mold 14, applying pressure and heat to the batch material or blank 9 until it adheres to the outer surface of the portion of the structural element 12.

[0029] According to an alternative embodiment (not shown), the step of applying pressure to the batch or slab 9 to cover the portion of the structural element 12 includes the following sub-steps: providing an autoclave vacuum bag; inserting the batch or slab 9 and the portion of the structural element 12 into the vacuum bag such that the batch or slab 9 faces the portion of the structural element 12; inserting the vacuum bag into an autoclave; and applying a vacuum within the vacuum bag, applying pressure and heat to the vacuum bag until the batch or slab 9 adheres to the outer surface of the portion of the structural element 12.

[0030] The batch or slab 9 may contain one or more layers of fiber material reinforced with a polymer matrix 10.

[0031] The batch or slab 9 may include a layer treated with an adhesive material 11, the layer being adapted to directly contact the outer surface of that portion of the structural element 12 and to adhere a composite coating to the structural element 12.

[0032] A method for manufacturing a metal structural component provided with a composite reinforcement, and various aspects and embodiments of the metal structural component provided with the composite reinforcement according to the present invention have been described. It should be understood that each embodiment may be combined with any other embodiment. Furthermore, the invention is not limited to the described embodiments, but may vary within the scope defined by the appended claims.

Claims

1. A method for manufacturing a metal structural component provided with a composite reinforcement, the method comprising the steps of: a) providing a batch or a slab of composite material (9); b) providing a vehicle structural element (12) made of a metal material; c) placing the batch or slab (9) so as to be laid on a portion of the structural element (12); and d) applying pressure to the batch or slab (9) so that it deforms itself while being pressed against the portion of the structural element (12) until it covers at least a portion of the profile of the portion of the structural element (12).

2. The method according to claim 1, wherein the structural element (12) is a component of an automotive suspension.

3. The method according to claim 2, wherein the structural element (12) is a suspension beam or a suspension knuckle.

4. The method according to claim 3, wherein the portion of the structural element (12) on which the composite batch or slab (9) is rested is an arm of a suspension knuckle, the arm being adapted to connect the knuckle to other elements of a suspension system.

5. The method according to any one of the preceding claims, wherein step (d) is performed by having the portion of the structural element (12) wrapped by composite material only from a single side of the portion, the single batch or slab (9) being initially laid on the single side.

6. The method according to any one of claims 1 to 4, comprising the steps of: providing two batches or slabs (9) of composite material and arranging the batches or slabs (9) so as to be laid on opposite sides of the portion of the structural element (12) so that, by performing step (d), the portion of the structural element (12) is covered with composite material from both of its opposite sides.

7. The method according to any one of the preceding claims, wherein step (d) comprises the following sub-steps: e) providing a mold (14) comprising two halves which together define a cavity adapted to house the batch or slab (9) and at least the portion of the structural element (12); f) inserting the batch or slab (9) into the cavity of one half and the portion of the structural element (12) into the cavity of the other half so that the batch or slab (9) faces the portion of the structural element (12); and g) closing the mold (14) while applying pressure and heat to the batch or slab (9) until it deforms itself to conform to the outer surface of the portion of the structural element (12).

8. The method according to any one of claims 1 to 6, wherein step (d) comprises the following sub-steps: h) providing a hot press tank vacuum bag; i) inserting the batch or slab (9) and the structural element portion (12) into the vacuum bag so that the batch or slab (9) faces the structural element portion (12); j) inserting the vacuum bag into a hot press tank; and k) applying pressure and heat to the batch or slab (9) and the structural element portion (12) until the batch or slab deforms itself to conform to the outer surface of the portion of the structural element (12). ​ k) applying vacuum inside the vacuum bag, pressure and heat to the vacuum bag until the batch or the blank (9) adheres to the outer surface of the portion of the structural element (12).

9. The method according to any one of the preceding claims, wherein the batch or the blank (9) comprises one or more layers of fiber reinforced material with a polymer matrix (10).

10. The method according to any one of the preceding claims, wherein the batch or the blank (9) comprises a layer treated with an adhesive material (11) adapted to be in direct contact with the outer surface of the portion of the structural element (12) and to adhere a composite coating to the structural element (12).

11. A reinforced structural element comprising a vehicle structural element (12) made of a metallic material, such as a cross member or a suspension knuckle, a portion of which is applied with a reinforcing plate (15) made of a composite material.

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