Method of manufacturing a consolidated fiber reinforced plastic part with a metal plate reinforcement and consolidated fiber reinforced plastic part with a metal plate reinforcement

Abstract

This invention relates to a method for manufacturing a bonded fiber-reinforced plastic component with metal plate reinforcement in the chassis area of ​​a vehicle, comprising the following steps: assembling a layered structure; setting a first layer of fiber-reinforced thermoplastic material, including a fiber-reinforced thermoplastic surface layer; placing a second layer of at least one metal plate on top of the first layer, the second layer partially covering the top of the first layer, the circumferential edge region of the top of the first layer remaining uncovered by the second layer; placing a third layer of fiber-reinforced thermoplastic material, the lower side of which is arranged on top of the second layer, the outer edge region of which is arranged on top of the first layer and completely covers the first layer, the third layer including the fiber-reinforced thermoplastic surface layer; heating the layered structure to a temperature higher than the melting temperature of the fiber-reinforced thermoplastic material; pressing the heated layered structure in a tooling mold to obtain a bonded fiber-reinforced plastic component; and cooling the bonded component.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a consolidated fiber-reinforced plastic component with a metal plate reinforcement and a consolidated fiber-reinforced plastic component with a metal plate reinforcement, particularly for the chassis region of a vehicle. Background Technology

[0002] Manufacturing methods and apparatus for consolidated fiber reinforced plastic parts (particularly for sandwich components made of plastic and metal sheets) are known in the prior art. A disadvantage of the prior art methods and apparatus is the requirement for high clamping forces during the manufacturing process, particularly in the compression molding step of long fiber reinforced thermoplastics. This, in turn, implies the need for molding presses with correspondingly high strength, large dimensions, and high molding pressures during manufacturing. Another disadvantage is the relatively high price of continuous fiber reinforcement, resulting in a correspondingly high price for the semi-finished product.

[0003] Another drawback of existing technologies is that when using sheet metal, these sheets must be protected from external influences, particularly corrosion, through appropriate processing. Therefore, complex manufacturing methods are required to improve the performance of mechanical components, especially to increase stiffness and / or strength. Summary of the Invention

[0004] In view of the above-mentioned shortcomings of the prior art, the object of the present invention is to provide an improved method for manufacturing a bonded fiber reinforced plastic part with a metal plate reinforcement, particularly for use in the chassis area of ​​a vehicle, and a bonded fiber reinforced plastic part with a metal plate reinforcement, wherein the plastic part with the metal plate reinforcement has reliable mechanical properties, and the manufacturing method is simplified and economical.

[0005] According to the present invention, the above-mentioned objective is achieved, according to the first aspect, by a method for manufacturing a bonded fiber reinforced plastic component having a metal plate reinforcement, and according to the second aspect, by a bonded fiber reinforced plastic component having a metal plate reinforcement.

[0006] According to a first aspect of the invention, a method is provided for manufacturing a bonded fiber reinforced plastic component having a metal plate reinforcement, particularly for use in the chassis region of a vehicle, the method comprising the following steps: A) Assemble the layered structure, including the following sub-steps: a1) A first layer of fiber-reinforced thermoplastic material is provided, the first layer having an upper side and a lower side, wherein the first layer includes at least one fiber-reinforced thermoplastic surface layer, wherein the at least one fiber-reinforced thermoplastic surface layer is formed such that it forms a continuous plate having a plate surface along an extending plane in the consolidation member. a2) A second layer of at least one metal plate is disposed on the upper side of the first layer, the second layer having an upper side and a lower side, wherein the second layer covers the upper side of the first layer in at least one local area, wherein at least one circumferential edge area of ​​the upper side of the first layer remains uncovered by the second layer. a3) A third layer of fiber-reinforced thermoplastic material is arranged, the third layer having an upper side and a lower side, wherein the lower side of the third layer is arranged on the upper side of the second layer and at least in the peripheral edge region on the upper side of the first layer and completely covers the first layer, wherein the third layer includes at least one fiber-reinforced thermoplastic surface layer, wherein the at least one fiber-reinforced thermoplastic surface layer is formed such that it forms a continuous plate having a plate surface along an extension plane in the consolidation member; B) Heating the layered structure from step a) to a temperature higher than the melting temperature of the fiber-reinforced thermoplastic material; C) Pressing the heated layered structure obtained in step B) in a tooling mold to obtain a consolidated fiber-reinforced plastic part, and D) Cooling and consolidation of fiber-reinforced plastic parts.

[0007] Preferably, the layered structure is assembled outside the press in step A) of the method.

[0008] According to the present invention, the first and third layers can be configured to be formed of the same thermoplastic material, wherein in step B), the layered structure is heated to a temperature higher than the melting temperature of the two uniform thermoplastic materials.

[0009] However, alternatively, according to the present invention, the first and third layers may be formed of different thermoplastic or plastic materials, each with a different melting temperature, and the layered structure may be heated in step B) to a temperature higher than the highest melting temperature of the different thermoplastic materials.

[0010] According to the present invention, a fiber-reinforced thermoplastic material layer is formed from at least one fiber-reinforced thermoplastic surface layer, wherein the at least one surface layer further has reinforcing fibers arranged in a woven or roving manner, the reinforcing fibers optionally being continuous fibers or long fibers, which are manufactured in a separate method and impregnated with a thermoplastic material in a second method step prior to the method according to the present invention. According to the present invention, the fiber-reinforced thermoplastic material layer may be formed from at least one continuous fiber-reinforced thermoplastic surface layer.

[0011] The surfaces of the first and third layers preferably have the same shape and size along the extending plane. This means that the first and third layers can preferably be aligned with each other or vertically aligned with each other.

[0012] According to the invention, the extension plane of the corresponding layer can be formed as flat or planar, but according to the invention, the plane can also be configured to extend concavely and / or convexly in at least a local area, for example to form a protrusion or depression within the bonded fiber-reinforced plastic component. In particular, the fiber-reinforced thermoplastic material layer can be configured to be formed from at least one fiber-reinforced thermoplastic surface layer, and in method step A), each extends along a flat plane, and in method step C), during pressing in the tooling die, each layer is given curvature at least locally along the extension plane to obtain a three-dimensional orientation along the extension plane of the layer.

[0013] At least one metal plate of the second layer can preferably be designed as a continuous metal plate, wherein the metal plate is smaller than the surface of the first layer in the extending plane of the first layer, such that at least one circumferential edge region on the upper side of the first layer remains uncovered by at least one metal plate of the second layer. However, according to the invention, the second layer can also be formed of a plurality of metal plates, which can be arranged on the upper side of the first layer at intervals, at least partially adjacent to each other, or overlapping each other.

[0014] Preferably, the multiple metal plates are all formed as rectangular strips and can be arranged parallel to each other on the upper side of the first layer. Here, when the multiple metal plates are arranged on the upper side of the first layer, the circumferential edge area of ​​the upper side of the first layer remains uncovered by the metal plates.

[0015] According to the invention, at least one metal plate may be configured to include local gaps along its respective plate surface, such as holes or grooves in the metal plate.

[0016] Preferably, method step A) further includes the following sub-step after sub-step a3): a4) A fourth layer of at least one metal plate is disposed on the upper side of the third layer, the fourth layer having an upper side and a lower side, wherein the fourth layer covers the upper side of the third layer in at least a partial area, and wherein at least one circumferential edge area of ​​the upper side of the third layer remains uncovered by the fourth layer; and a5) A fifth layer of fiber-reinforced thermoplastic material is arranged, the fifth layer having an upper side and a lower side, wherein the fifth layer includes at least one fiber-reinforced thermoplastic surface layer, wherein the lower side of the fifth layer is arranged on the upper side of the fourth layer, and is arranged on the upper side of the third layer at least in the peripheral edge region, and completely covers the third layer, wherein at least one fiber-reinforced thermoplastic surface layer is formed such that it forms a continuous plate having a plate surface along an extension plane in the consolidation member.

[0017] The surfaces of the third and fifth layers preferably have the same shape and dimensions as the first and / or third layers along the extending plane. This means that they can be aligned with each other or vertically aligned.

[0018] At least one metal plate of the fourth layer may preferably be designed to be similar to at least one metal plate of the second layer, although the outer edge region of the upper side of the third layer remains uncovered by at least one metal plate of the fourth layer.

[0019] The uncovered circumferential edge regions between the first and third layers and / or between the third and fifth layers cause the first and third layers and / or the third and fifth layers to abut against each other with their respective upper and lower sides, and during the pressing of the heated layered structure, the second or fourth layer is completely surrounded or embedded in the fiber-reinforced thermoplastic fiber composite layer.

[0020] Preferably, the metal plate is made of metal or metal alloy (especially aluminum, steel or titanium).

[0021] Preferably, the first and / or third and / or fifth layer (if present) comprises a plurality of fiber-reinforced thermoplastic surface layers, wherein the plurality of surface layers overlap and / or are arranged at least adjacent to each other along an extending plane to form respective layers, and preferably are partially bonded or adhered to each other.

[0022] The terms "bonding" or "adhesion" used in this article include methods such as adhesive bonding (especially structural bonding or film bonding), welding (especially ultrasonic welding or laser welding or hot plate welding or resistance welding), or thermal bonding.

[0023] Preferably, this method includes the following additional sub-steps after method step A) and before method step B): a6-1) At least one piece of fiber-reinforced thermoplastic material is locally arranged as a reinforcing layer on the upper side of the third layer, the at least one piece of fiber-reinforced thermoplastic material having an upper side and a lower side, wherein the reinforcing layer is preferably formed of at least one fiber-reinforced thermoplastic surface layer for locally increasing the wall thickness and / or for forming a rib structure in the bonded fiber-reinforced plastic component.

[0024] The wall thickness of the bonded fiber reinforced plastic component is measured perpendicular to the plane of extension of each layer. The lower side of the first layer forms the lower side of the bonded fiber reinforced plastic component, and the upper side of the third layer or the upper side of the fifth layer (if present) forms the upper side of the bonded fiber reinforced plastic component.

[0025] Preferably, at least one fiber-reinforced thermoplastic material is arranged as a reinforcing layer in the region between two adjacent metal plates along the extended plane.

[0026] Preferably, this method includes the following additional sub-steps after method step A) and before method step B): a6-1) At least one piece of fiber-reinforced thermoplastic material is locally arranged as a reinforcing layer on the upper side of the fifth layer, the at least one piece of fiber-reinforced thermoplastic material having an upper side and a lower side, wherein the reinforcing layer is preferably formed of at least one fiber-reinforced thermoplastic surface layer for locally increasing the wall thickness and / or for forming a rib structure in the bonded fiber-reinforced plastic component.

[0027] At least one piece of fiber-reinforced thermoplastic material can be formed, for example, in the form of a strip to form a rib structure extending in the form of a strip on the upper side of the fifth layer.

[0028] Preferably, the first and third layers are aligned vertically along their respective extension planes such that the surfaces of each layer coincide in the extension planes, and / or if a fifth layer exists, the third and fifth layers are aligned vertically along their respective extension planes such that the surfaces of each layer coincide in the extension planes.

[0029] Here, these layers form a common side or side surface in a bonded fiber-reinforced plastic component.

[0030] Preferably, this method further includes the following method steps before method step A): a0-1) Cut at least one fiber-reinforced thermoplastic surface layer to form a corresponding layer of fiber-reinforced thermoplastic material.

[0031] Preferably, this method further includes the following method steps before method step A): a0-2) Cut at least one metal sheet to form a second and / or fourth layer (if present), in particular cutting to a size smaller than the sheet surface of the fiber-reinforced thermoplastic layer, such that the second and / or fourth layers in the bonded fiber-reinforced plastic component are surrounded by corresponding layers of fiber-reinforced thermoplastic material.

[0032] Here, the size of the metal sheet is smaller than the surface area of ​​the fiber-reinforced thermoplastic layer, which particularly allows the metal sheet to be arranged such that the edge regions of the first, third, and possibly fifth layers remain uncovered. Preferably, the first, third, and possibly fifth layers can therefore be bonded or adhered and / or thermally bonded together, especially in the edge regions, such that at least one metal sheet of the second and / or fourth layers is surrounded by the corresponding layer of fiber-reinforced thermoplastic material. In particular, this allows the edge regions of the first, third, and possibly fifth layers to be formed in a press, for example, to form a convex wall shape, without requiring a forming step for the metal sheet.

[0033] Preferably, this method further includes the following method steps before method step A): a0-3) Treat the upper and / or lower sides of at least one metal plate of the second and / or fourth layers to improve adhesion properties relative to the fiber-reinforced thermoplastic material.

[0034] In this case, the step of treating the upper and / or lower sides of at least one metal plate of the second and / or fourth layers to improve adhesion properties relative to the fiber-reinforced thermoplastic material includes coating the upper and / or lower sides with an tackifier (particularly a polymeric tackifier). For example, the tackifier may be coated onto the respective surfaces or applied in the form of a thin film.

[0035] Preferably, this method includes the following additional sub-steps after method step a6-1) and before method step B): a7-1) Punctually bond or adhere at least one reinforcing layer to the upper side of the third layer; or The following sub-steps are included after method step a6-2) and before method step b): a7-1) At least one reinforcing layer is dot-bonded or dot-adhered to the upper side of the fifth layer; The reinforcing layers are locally secured to the top side of the third or fifth layer of fiber-reinforced thermoplastic material via spot bonding or adhesion, and are thus fixed to prevent slippage. This facilitates the safe handling of the layered structure before it is solidified, without the risk of the layers slipping against each other.

[0036] Preferably, method step A) further includes the following sub-steps: a8) To spot bond or spot adhere at least one metal plate to the upper side of a layer disposed directly below a layer of at least one metal plate and / or to the lower side of a layer disposed directly above a layer of at least one metal plate.

[0037] At least one metal plate is locally secured to the upper side of the layer directly beneath it and / or the lower side of the fiber-reinforced thermoplastic layer directly above it by point bonding or adhesion, and is thus secured to prevent slippage. This, in turn, facilitates the transport of the layered structure.

[0038] Preferably, method step A) further includes the following sub-steps: a9) Point bonding or spot adhesion of the upper and opposite lower sides of two overlapping surface areas of the fiber-reinforced thermoplastic material layer.

[0039] Here, adjacent layers are at least partially thermally bonded to each other, especially at the edge points of the respective layers, to form a transport-stable layered structure.

[0040] Preferably, in step C), the layered structure is sequentially pressed in a tool mold having a leading tool area and a following tool area, particularly using a shearing tool, to form different wall thicknesses and / or shaped upper and / or lower sides in the bonded fiber reinforced plastic part, particularly rib-like structures on the upper and / or lower sides of the bonded fiber reinforced plastic part, wherein areas with increased wall thickness are pressed by the following tool area.

[0041] Preferably, the forming pressure of the leading tooling area and the following tooling area is the same. Alternatively, the forming pressure of the leading tooling area may be greater than or less than the forming pressure of the following tooling area. Preferably, the following tooling area is configured for locally restricted compression forming, such as in the region of the reinforcing layer. Preferably, the leading tooling area is arranged for pressing a base structure comprising a first layer, a second layer, a third layer, and a fourth and fifth layer (if present).

[0042] Preferably, the method further includes the method step according to method step D): E) Create grooves and / or trim the surface of each layer in the bonded fiber reinforced plastic component.

[0043] Here, the bonded fiber reinforced plastic parts can be further processed, preferably by machining, such as forming connection points or specific geometries.

[0044] Preferably, the bonded fiber reinforced plastic parts are post-processed using a punch press, and / or the post-processing includes at least one of drilling, milling, waterjet cutting or laser cutting.

[0045] Punch presses enable precise and rapid machining, especially of hard materials. Post-processing techniques, such as drilling, milling, waterjet cutting, and / or laser cutting, can produce, for example, individual grooves and / or geometrically complex grooves and / or side recesses.

[0046] Preferably, after method step E), threaded connection points are formed on the consolidated fiber reinforced plastic component, particularly for fastening to the vehicle chassis, especially by providing inserts and / or bushings.

[0047] Preferably, the threaded connection point is formed in a groove that has been previously machined. Alternatively or additionally, the threaded connection point is formed independently of the groove.

[0048] Preferably, transfer fixtures, particularly vacuum fixtures and / or pin fixtures, are used to pick up and transfer structural and / or bonded fiber-reinforced plastic components between method steps.

[0049] In particular, the bonded fiber reinforced plastic component is transferred between various method steps and / or sub-steps. According to the invention, the bonded fiber reinforced plastic component can also be moved, particularly displaced, during method steps or sub-steps using a transfer fixture.

[0050] Preferably, the fiber-reinforced thermoplastic material layers have the same material properties or different material properties, particularly different fiber densities and / or different porosities and / or different fiber types and / or different flame-retardant additives.

[0051] Preferably, the first layer (particularly the underside of the first layer) has flame-retardant additives to protect the bonded fiber-reinforced plastic components on the roadside when used in the chassis area of ​​a vehicle.

[0052] In particular, the third and / or fifth layers may have a higher pore volume content than the underlying fiber-reinforced thermoplastic material layer.

[0053] Preferably, prior to step A), the corresponding metal sheet is pre-stamped into a three-dimensional shape, particularly forming reinforcing ribs.

[0054] This can improve the performance of mechanically bonded fiber reinforced plastic parts, especially the stiffness and / or strength of the bonded fiber reinforced plastic parts.

[0055] According to the present invention, in a preferred embodiment, the fiber-reinforced thermoplastic material layers can each be formed as glass fiber mat-reinforced thermoplastic material (GMT). In this case, the GMT is formed from at least one glass fiber mat-reinforced thermoplastic surface layer, wherein the at least one surface layer comprises a glass fiber mat comprising continuous glass fibers or long-fiber glass fibers, which are manufactured in a separate method and impregnated with a thermoplastic material in another method step, wherein the above-mentioned method step is performed prior to the method step according to the present invention.

[0056] According to a second aspect of the invention, a consolidated fiber-reinforced plastic component having a metal plate reinforcement is provided, preferably for use in the chassis region of a vehicle, and particularly manufactured according to the method of the first aspect of the invention, the consolidated fiber-reinforced plastic component comprising: - A first layer of fiber-reinforced thermoplastic material, the first layer having an upper side and a lower side, wherein the first layer includes at least one fiber-reinforced thermoplastic surface layer, wherein the at least one fiber-reinforced thermoplastic surface layer is formed such that it forms a continuous plate having a plate surface along an extending plane in the bonded fiber-reinforced plastic member. - A second layer of at least one metal plate, the second layer having an upper side and a lower side, wherein the second layer covers the upper side of the first layer in at least one local area, wherein at least one circumferential edge area of ​​the upper side of the first layer remains uncovered by the second layer; - A third layer of fiber-reinforced thermoplastic material, the third layer having an upper side and a lower side, wherein the lower side of the third layer is disposed on the upper side of the second layer and at least in the peripheral edge region disposed on the upper side of the first layer and completely covering the first layer, wherein the third layer includes at least one fiber-reinforced thermoplastic surface layer, wherein the at least one fiber-reinforced thermoplastic surface layer is formed such that it forms a continuous plate having a plate surface along an extended plane in the bonded fiber-reinforced plastic component.

[0057] Preferably, the consolidated fiber reinforced plastic component further includes: - A fourth layer of at least one metal plate, the fourth layer having an upper side and a lower side, the fourth layer being on top of the third layer, wherein the fourth layer covers the upper side of the third layer in at least one local area, and wherein at least one circumferential edge area of ​​the upper side of the third layer is not covered by the fourth layer; and - A fifth layer of fiber-reinforced thermoplastic material, the fifth layer having an upper side and a lower side, wherein the fifth layer includes at least one fiber-reinforced thermoplastic surface layer, wherein the lower side of the fifth layer is disposed on the upper side of the fourth layer, and is disposed on the upper side of the third layer at least in the peripheral edge region, and completely covers the third layer, wherein at least one fiber-reinforced thermoplastic surface layer is formed such that it forms a continuous plate having a plate surface along an extending plane in the bonded fiber-reinforced plastic component.

[0058] Preferably, the consolidated fiber reinforced plastic component further includes: - At least one piece of fiber-reinforced thermoplastic material having an upper side and a lower side as a reinforcing layer locally located on the upper side of the third layer, wherein the reinforcing layer is preferably formed of at least one fiber-reinforced thermoplastic surface layer for locally increasing the wall thickness of the bonded fiber-reinforced plastic component and / or for forming a surface profile.

[0059] Preferably, the fiber-reinforced thermoplastic material layer is at least partially formed of glass fiber mat-reinforced thermoplastic material (GMT), wherein at least one fiber-reinforced thermoplastic surface layer is formed as at least one glass fiber mat-reinforced thermoplastic surface layer.

[0060] According to the present invention, in a preferred embodiment, the fiber-reinforced thermoplastic material layers may each be formed as glass fiber mat-reinforced thermoplastic material (GMT), which is further formed by at least one glass fiber mat-reinforced thermoplastic surface layer, wherein the at least one surface layer comprises glass fiber mat, the glass fiber mat comprising continuous glass fibers or long-fiber glass fibers, the continuous glass fibers or long-fiber glass fibers being manufactured in a separate method and impregnated with thermoplastic material in another method step, wherein the aforementioned method step is performed prior to the method step according to the present invention.

[0061] Preferably, the lower side of the first layer forms the lower side of the bonded fiber reinforced plastic component, and the upper side of the third layer or the upper side of the fifth layer (if present) forms the upper side of the bonded fiber reinforced plastic component. Preferably, the lower side of the bonded component is aligned with the road side, and the upper side of the bonded component is aligned with the vehicle.

[0062] Preferably, this method is further improved by utilizing the features of the above-described and inverted consolidated fiber reinforced plastic parts. Attached Figure Description

[0063] In the following description, exemplary embodiments of the method according to the invention and the consolidated fiber reinforced plastic parts according to the invention are explained with reference to the accompanying drawings.

[0064] In the attached diagram: Figure 1A This is a side view schematic diagram of the first layer of a fiber-reinforced thermoplastic material according to an exemplary embodiment of the present invention; Figure 1B This is a top view schematic diagram of the first layer of a fiber-reinforced thermoplastic material according to an exemplary embodiment of the present invention; Figure 2A This is a top view schematic diagram of the second layer of a continuous metal plate according to an exemplary embodiment of the present invention; Figure 2B This is a top view schematic diagram of a second layer of multiple spaced metal plates according to an exemplary embodiment of the present invention; Figure 2C This is a top view schematic diagram of the second layer of a metal plate with local gaps according to an exemplary embodiment of the present invention; Figure 3A This is a side view schematic diagram of a first layer of fiber-reinforced thermoplastic material and a second layer of multiple spaced metal plates according to an exemplary embodiment of the present invention. Figure 3B This is a top view schematic diagram of a first layer of fiber-reinforced thermoplastic material and a second layer of multiple spaced metal plates according to an exemplary embodiment of the present invention; Figure 4A This is a side view schematic diagram of the adhesion of a first layer of fiber-reinforced thermoplastic material to a plurality of spaced metal plates, according to an exemplary embodiment of the present invention. Figure 4B This is a top view schematic diagram of a first layer of fiber-reinforced thermoplastic material and a second layer of multiple spaced metal plates having bonding points, according to an exemplary embodiment of the present invention. Figure 5A This is a schematic side view of a second layer, in which the first and third layers of fiber-reinforced thermoplastic material are adhered to a plurality of spaced metal plates, according to an exemplary embodiment of the present invention. Figure 5BThis is a top view schematic diagram of a third layer of fiber-reinforced thermoplastic material and a second layer of multiple spaced metal plates according to an exemplary embodiment of the present invention; Figure 6A This is a side view schematic diagram of the adhesion of a first and third layer of fiber-reinforced thermoplastic material to a plurality of spaced metal plates, and the second layer of the adhered reinforcing layer, according to an exemplary embodiment of the present invention. Figure 6B This is a top view schematic diagram of the third layer of a fiber-reinforced thermoplastic material having a reinforcing layer s, according to an exemplary embodiment of the present invention; Figure 7 This is a side view schematic diagram of the adhesion of the first, third, and fifth layers of fiber-reinforced thermoplastic material to a plurality of spaced metal plates, the second and fourth layers, and the adhered reinforcing layers, according to an exemplary embodiment of the present invention. Figure 8 This is a schematic side view of a layered structure having a leading tool area and a following tool area in a tool mold according to an exemplary embodiment of the present invention; Figure 9 This is a schematic diagram of a bonded fiber-reinforced plastic component having a metal plate reinforcement according to an exemplary embodiment of the present invention. Detailed Implementation

[0065] The exemplary embodiments shown are illustrative, and therefore the invention is not limited to the dimensions and / or length proportions shown. Furthermore, the number of features shown is exemplary and may differ from the shown number.

[0066] In an exemplary embodiment of the present invention, Figure 1A A schematic side view of a first layer 10 of fiber-reinforced thermoplastic material is shown, the first layer 10 having an upper side 102 and an opposite lower side 101. Preferably, a third layer 20 and / or a fifth layer 30 of fiber-reinforced thermoplastic material are formed similarly to the first layer 10. As an example, an extended plane 11 of the first layer 10 is shown for illustrative purposes, where this is merely a hypothetical reference plane.

[0067] In an exemplary embodiment of the present invention, Figure 1B A schematic top view of a first layer 10 of fiber-reinforced thermoplastic material is shown, having an upper side 102 and a virtual extending plane 11, wherein the extending plane 11, serving as a reference plane, is not limited in size to this surface. Here, the first layer 10 of the fiber-reinforced thermoplastic material is exemplaryly shaped as a continuous layer of fiber-reinforced thermoplastic surface layers. Preferably, the first layer 10 includes at least one fiber-reinforced thermoplastic surface layer, wherein the at least one surface layer may have reinforcing fibers arranged in a woven or roving manner, preferably having continuous fibers or long fibers. Figure 1A and Figure 1BAs shown in the exemplary embodiment, the extension plane 11 of the first layer 10 is flat or planar. However, the extension plane may also be concave and / or convex at least in local areas, for example, to form a protrusion or depression within the consolidation member.

[0068] Figures 2A to 2C A top view schematic diagram of a second layer 12 of at least one metal plate in an exemplary embodiment of the present invention is shown. Preferably, a fourth layer 14 of at least one metal plate is formed similarly to the second layer 12. In particular, at least one metal plate of the second layer 12 in the extending plane 11 of the first layer 10 is designed to be smaller than the plate surface of the first layer 10, such that at least one circumferential edge region of the upper side 102 of the first layer 10 remains uncovered by at least one metal plate of the second layer 12.

[0069] like Figure 2A As shown, at least one metal plate of the second layer 12 can preferably be formed as a continuous metal plate. Alternatively, the second layer 12 can also be formed of several metal plates. Figure 2B As illustrated, the metal plates can be arranged at intervals. Alternatively or additionally, multiple metal plates can also be arranged at least partially adjacent to or overlapping each other. Preferably, the multiple metal plates are designed as rectangular strips and are arranged parallel to each other. Figure 2C Another embodiment of the second layer 12 is shown, wherein at least one metal plate includes a localized gap in the form of a groove. Alternatively or additionally, for example, the localized gap may also be designed as a hole or a slot.

[0070] In an exemplary embodiment of the present invention, Figure 3A The side view shows a layered structure with a first layer 10 and a second layer 12. Here, the second layer 12 is composed of a plurality of spaced-apart metal plates arranged on the upper side 102 of the first layer. Figure 3B As shown, the plurality of metal plates of the second layer 12 can be formed as rectangular strips and arranged parallel to each other on the upper side 102 of the first layer 10. Here, the second layer 12 is arranged such that at least one circumferential edge region of the first layer 10 is not covered by the metal plates of the second layer.

[0071] exist Figure 4A An exemplary embodiment is shown, wherein the underside of the second layer 12 is dot-bonded or adhered 60 to the upper side 102 of the first layer 10. Thus, in the layered structure, the metal plate of the second layer 12 is fixed to the surface 102 of the first layer 10 to prevent slippage. Alternatively or additionally, the dot-bonded or adhered 60 may also be formed on the upper side of the second layer 12 to fix the second layer to the underside 201 of the third layer 20 to prevent slippage.

[0072] Figure 5AA layered structure in an exemplary embodiment is shown, comprising: a first layer 10 having a lower side 101 and an upper side 102; a second layer 12, dot-bonded or dot-adhered 60 to the upper side 102, wherein the second layer 12 comprises a plurality of spaced metal plates; and a third layer 20 having a lower side 201 and an upper side 202, wherein the third layer comprises at least one fiber-reinforced thermoplastic surface layer and is dot-bonded or dot-adhered 60 to the upper side of the second layer 12 from the lower side 201. The lower side 201 of the third layer 20 is preferably dot-bonded 62 to the upper side 102 of the first layer 10. Specifically, the first layer 10 and the third layer 20 are bonded to each other in edge regions. However, alternatively or additionally, the first layer 10 and the third layer 20 may also preferably be dot-bonded to each other in areas not covered by the second layer 12. The dot-bonding 62 between the first and third layers may be the same dot-bonding or dot-adhered 60 as between the first layer 10 or the third layer 20 and the second layer 12. Alternatively, the bonding 62 between the first layer 10 and the third layer 20 is different from the bonding or adhesion 60 between the first layer 10 or the third layer 20 and the second layer 12.

[0073] Figure 5B A top view of a layered structure having an upper side 202 of a third layer 20 is shown in an exemplary embodiment, wherein the second layer 12 located between the first layer 10 and the third layer 20 is shown for illustrative purposes only.

[0074] Figure 6A An exemplary embodiment is shown, wherein, in addition to the first layer 10, the second layer 12, and the third layer 20, the layered structure further includes a reinforcing layer 50 on the upper side 202 of the third layer 20. The reinforcing layer 50 is preferably made of at least one fiber-reinforced thermoplastic surface layer, such that the wall thickness can be locally increased and / or a rib-like structure can be formed in the bonded component. Preferably, as shown... Figure 6A As shown, at least one piece of fiber-reinforced thermoplastic material is arranged as a reinforcing layer in the region between two adjacent metal plates. Preferably, the reinforcing layer 50 is spot-bonded 62 from the lower side to the upper side 202 of the third layer 20, such that the reinforcing layer is fixed in the layered structure to prevent slippage. The spot bonding or adhesion between the layers creates a transfer-stable layered structure that can be transferred between process steps or repositioned during process steps or sub-steps, particularly by means of a transfer fixture.

[0075] Figure 6B The layered structure in the exemplary embodiment is shown in top view, wherein the reinforcing layer 50 is arranged on the upper side 202 of the third layer 20 in the form of a plurality of spaced fiber-reinforced thermoplastic material strips.

[0076] Figure 7Another embodiment of the invention is shown, wherein the layered structure includes a first layer 10, a second layer 12, a third layer 20, a fourth layer 14, a fifth layer 30, and a reinforcing layer 50. The second and fourth layers are each spot-bonded or spot-adheded 60 to the corresponding upper sides 102, 201 or lower sides 201, 301 of adjacent layers 10, 20, 30. The upper side 102 of the first layer 10 is spot-bonded 62 to the lower side 201 of the second layer 20, and the upper side 202 of the second layer 20 is spot-bonded 62 to the lower side 301 of the fifth layer 30. The lower side of the reinforcing layer 50 is spot-bonded to the upper side 302 of the fifth layer 30. Here, the first layer 10, the third layer 20, and the fifth layer 30 are flush with each other. Preferably, the second layer 12 and the fourth layer 14 are vertically aligned to form a sandwich structure. In particular, the reinforcing layer 50 is disposed in the region between two adjacent metal plates of the second layer 12 and the fourth layer 14.

[0077] Preferably, in one or all embodiments, the fiber-reinforced thermoplastic material layer is at least partially formed of glass fiber mat-reinforced thermoplastic material (GMT), wherein at least one fiber-reinforced thermoplastic surface layer is formed as at least one glass fiber mat-reinforced thermoplastic surface layer.

[0078] Figure 8 An exemplary embodiment illustrates the pressing 400 of a heated layered structure. The layered structure is arranged in a tool mold 402, wherein the first layer 10 is aligned with the bottom of the tool mold, and the reinforcing layer 50 is aligned with the pressing tool. The pressing tool has a leading tool area 404 and a following tool area 406, allowing the layered structure to be pressed sequentially.

[0079] Figure 9 A schematic diagram of an exemplary embodiment of the invention illustrates a bonded fiber-reinforced plastic component 500 having metal plate reinforcements 12, 14. In the bonded component, the first layer 10, the third layer 20, and the fifth layer 30 each form a common sidewall and completely surround the metal plates of the second layer 12 and the fourth layer 14. This protects the metal plates from corrosion. The reinforcement layer 50 forms a rib-like structure on the upper side of the bonded component 500, wherein threaded connection points, particularly for fastening to a vehicle chassis, can preferably be formed in the rib-like structure, for example, by providing inserts and / or bushings.

Claims

1. A method for manufacturing a bonded fiber reinforced plastic component with sheet metal reinforcement in the chassis region of a vehicle, comprising the following steps: a) Assemble the layered structure, including the following sub-steps: a1) A first layer of fiber-reinforced thermoplastic material is provided, the first layer having an upper side and a lower side, wherein the first layer includes at least one fiber-reinforced thermoplastic surface layer, wherein the at least one fiber-reinforced thermoplastic surface layer is formed such that it forms a continuous plate having a plate surface along an extending plane in the consolidation member. a2) A second layer of at least one metal plate is disposed on the upper side of the first layer, the second layer having an upper side and a lower side, wherein the second layer covers the upper side of the first layer in at least a partial area, wherein at least a circumferential edge area of ​​the upper side of the first layer remains uncovered by the second layer; a3) A third layer of fiber-reinforced thermoplastic material is arranged, the third layer having an upper side and a lower side, wherein the lower side of the third layer is arranged on the upper side of the second layer and at least in the peripheral edge region on the upper side of the first layer and completely covers the first layer, wherein the third layer includes at least one fiber-reinforced thermoplastic surface layer, wherein the at least one fiber-reinforced thermoplastic surface layer is formed such that it forms a continuous plate having a plate surface along an extension plane in the consolidation member; b) Heating the layered structure from step a) to a temperature higher than the melting temperature of the fiber-reinforced thermoplastic material; c) Press the heated layered structure obtained in step b) in a tooling mold to obtain a consolidated fiber-reinforced plastic part, and d) Cool the solidified component.

2. The method according to claim 1, wherein method step a) further comprises the following sub-steps: a4) A fourth layer of at least one metal plate is disposed on the upper side of the third layer, the fourth layer having an upper side and a lower side, wherein the fourth layer covers the upper side of the third layer in at least a partial area, and wherein at least a circumferential edge area of ​​the upper side of the third layer remains uncovered by the fourth layer; and a5) A fifth layer of fiber-reinforced thermoplastic material is arranged, the fifth layer having an upper side and a lower side, wherein the fifth layer includes at least one fiber-reinforced thermoplastic surface layer, wherein the lower side of the fifth layer is arranged on the upper side of the fourth layer and at least in the peripheral edge region on the upper side of the third layer and completely covers the third layer, wherein the at least one fiber-reinforced thermoplastic surface layer is formed such that it forms a continuous plate having a plate surface along an extension plane in the consolidation member.

3. The method according to claim 1 or 2, wherein the first layer and / or the third layer and / or, if present, the fifth layer comprises a plurality of fiber-reinforced thermoplastic surface layers, wherein the plurality of surface layers overlap and / or are arranged at least adjacent to each other along an extending plane to form respective layers, and are preferably partially bonded or adhered to each other.

4. The method according to claim 1 or 2, if this is related to claim 1, further comprising the following sub-steps after method step a) and before method step b): a6-1) At least one piece of fiber-reinforced thermoplastic material is locally arranged as a reinforcing layer on the upper side of the third layer, the at least one piece of fiber-reinforced thermoplastic material having an upper side and a lower side, wherein the reinforcing layer is preferably formed of at least one fiber-reinforced thermoplastic surface layer for locally increasing the wall thickness and / or for forming a rib structure in the consolidated fiber-reinforced plastic component.

5. The method according to claim 2 or 3, as is relevant to claim 2, further comprising the following sub-steps after method step a) and before method step b): a6-1) At least one piece of fiber-reinforced thermoplastic material is locally arranged as a reinforcing layer on the upper side of the fifth layer, the at least one piece of fiber-reinforced thermoplastic material having an upper side and a lower side, wherein the reinforcing layer is preferably formed of at least one fiber-reinforced thermoplastic surface layer for locally increasing the wall thickness and / or for forming a rib structure in the consolidated fiber-reinforced plastic component.

6. The method according to any one of the preceding claims, wherein the first layer and the third layer are vertically aligned along their respective extending planes such that the surface surfaces of the layers coincide in the extending planes, and / or if a fifth layer is present, the third layer and the fifth layer are vertically aligned along their respective extending planes such that the surface surfaces of the layers coincide in the extending planes.

7. The method according to any one of the preceding claims, further comprising the following method steps before method step a): (a0-1) Cut the at least one fiber-reinforced thermoplastic surface layer to form a corresponding layer of fiber-reinforced thermoplastic material.

8. The method according to any one of the preceding claims, further comprising the following method steps before method step a): a0-2) Cut the at least one metal plate to form the second layer and / or, if present, the fourth layer, particularly cutting it to a size smaller than the plate surface of the fiber-reinforced thermoplastic layer, such that the second layer and / or the fourth layer in the bonded fiber-reinforced plastic component are surrounded by corresponding layers of the fiber-reinforced thermoplastic material.

9. The method according to any one of the preceding claims, further comprising the following method steps before method step a): (a0-3) Treat the upper and / or lower sides of at least one metal plate of the second and / or fourth layers to improve adhesion properties relative to the fiber-reinforced thermoplastic material.

10. The method according to claim 4 or 5, The following sub-steps are included after method step a6-1) and before method step b): a7-1) The lower side of the at least one reinforcing layer is spot-bonded or spot-adhered to the upper side of the third layer; or The following sub-steps are included after method step a6-2) and before method step b): a7-1) The lower side of the at least one reinforcing layer is spot-bonded or spot-adhered to the upper side of the fifth layer.

11. The method according to any one of the preceding claims, wherein method step a) further comprises the following sub-steps: a8) To spot bond or adhere the corresponding layer of the at least one metal plate to the upper side of a layer disposed directly below the layer of the at least one metal plate and / or to the lower side of a layer disposed directly above the layer of the at least one metal plate.

12. The method according to any one of the preceding claims, wherein method step a) further comprises the following sub-steps: a9) Point bonding or spot adhesion of the upper and opposite lower sides of the two overlapping surface regions of the fiber-reinforced thermoplastic material layer.

13. The method according to any one of the preceding claims, wherein in step c), the layered structure is sequentially pressed in a tool die having a leading tool area and a following tool area, particularly using a shearing tool die, to form ribs of different wall thicknesses and / or shaped upper and / or lower sides in the bonded fiber reinforced plastic part, particularly on the upper and / or lower sides of the bonded fiber reinforced plastic part, wherein the areas with increased wall thickness are pressed by the following tool area.

14. The method according to any one of the preceding claims further includes the following method steps according to method step d): e) The plate surface in which grooves and / or trimming layers are formed in the consolidated fiber reinforced plastic component.

15. The method of claim 14, wherein the bonded fiber reinforced plastic component is post-processed using a punch press, and / or the post-processing includes at least one step of drilling, milling, waterjet cutting, or laser cutting.

16. The method according to claim 13 or 14, wherein after step e), threaded connection points for fastening to a vehicle chassis are formed on the consolidated fiber-reinforced plastic component, particularly by providing inserts and / or bushings.

17. The method according to any one of the preceding claims, wherein the structure and / or the bonded fiber reinforced plastic component is picked up and transferred between the method steps using a transfer fixture, particularly a vacuum fixture and / or a pin clamp.

18. The method according to any one of the preceding claims, wherein the fiber-reinforced thermoplastic material layer has the same material properties or different material properties, particularly different fiber densities and / or different porosities and / or different fiber types and / or different flame retardant additives.

19. The method according to any one of the preceding claims, wherein prior to step a), the corresponding metal sheet is pre-stamped into a three-dimensional shape, particularly for forming reinforcing ribs.

20. The method according to any one of the preceding claims, wherein the fiber-reinforced thermoplastic material layer is at least partially formed of glass fiber mat-reinforced thermoplastic material (GMT), wherein the at least one fiber-reinforced thermoplastic surface layer is formed as at least one glass fiber mat-reinforced thermoplastic surface layer.

21. A bonded fiber reinforced plastic component having a metal plate reinforcement in the chassis region of a vehicle, the bonded fiber reinforced plastic component being manufactured, in particular, by means of the method according to any one of the preceding claims, comprising: - A first layer of fiber-reinforced thermoplastic material, the first layer having an upper side and a lower side, wherein the first layer includes at least one fiber-reinforced thermoplastic surface layer, wherein the at least one fiber-reinforced thermoplastic surface layer is formed such that it forms a continuous plate having a plate surface along an extending plane in the consolidated fiber-reinforced plastic member; - At least one metal plate with a second layer having an upper side and a lower side, wherein the second layer covers the upper side of the first layer in at least one local area, wherein at least one circumferential edge area of ​​the upper side of the first layer remains uncovered by the second layer; - A third layer of fiber-reinforced thermoplastic material, the third layer having an upper side and a lower side, wherein the lower side of the third layer is disposed on the upper side of the second layer and at least in the peripheral edge region on the upper side of the first layer and completely covers the first layer, wherein the third layer includes at least one fiber-reinforced thermoplastic surface layer, wherein the at least one fiber-reinforced thermoplastic surface layer is formed such that it forms a continuous plate having a plate surface along an extending plane in the bonded fiber-reinforced plastic component.

22. The bonded fiber reinforced plastic component according to claim 21, further comprising: - At least one fourth layer of a metal plate, the fourth layer having an upper side and a lower side, the fourth layer being on top of the third layer, wherein the fourth layer covers the upper side of the third layer in at least one local area, and wherein at least one circumferential edge area of ​​the upper side of the third layer is not covered by the fourth layer; and - A fifth layer of fiber-reinforced thermoplastic material, the fifth layer having an upper side and a lower side, wherein the fifth layer includes at least one fiber-reinforced thermoplastic surface layer, wherein the lower side of the fifth layer is disposed on the upper side of the fourth layer and at least in the peripheral edge region is disposed on the upper side of the third layer and completely covers the third layer, wherein at least one fiber-reinforced thermoplastic surface layer is formed such that it forms a continuous plate having a plate surface along an extending plane in the bonded fiber-reinforced plastic component.

23. The bonded fiber reinforced plastic component according to claim 20 or 21, further comprising: - At least one piece of fiber-reinforced thermoplastic material having an upper side and a lower side as a reinforcing layer located locally on the upper side of the third layer, wherein the reinforcing layer is preferably formed of at least one fiber-reinforced thermoplastic surface layer for locally increasing the wall thickness of the bonded fiber-reinforced plastic component and / or for forming a surface profile.

24. The consolidated fiber-reinforced plastic component according to any one of claims 21 to 23, wherein the fiber-reinforced thermoplastic material layer is at least partially formed of glass fiber mat-reinforced thermoplastic material (GMT), wherein the at least one fiber-reinforced thermoplastic surface layer is formed as at least one glass fiber mat-reinforced thermoplastic surface layer.

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