Methods for repairing composite-reinforced metallic structures in hybrid construction

Abstract

Method for repairing a damaged area (2) of a metal-plastic hybrid component (1) of a structural assembly (3), wherein the plastic hybrid component (1) has at least one reinforcement section (5) having a reinforcement element (4), the method comprising the following steps: a) Cutting through the plastic hybrid component (1) above and below the damaged area (2) along a first and second defined dividing line (6, 6') through a reinforcement section (5) each; b) Removal of the detached component section (10); c) Providing and inserting a precisely fitting replacement part (10') into the opening of the separated plastic hybrid component (1); d) Connecting the spare part (10') to the plastic hybrid component (1) at or adjacent to the separation lines (6, 6'); e) Attaching one prefabricated reinforcement element (4) in the area of ​​the respective reinforcement section (5).

Description

[0001] The invention relates to a method for repairing a damaged area of ​​a metal-plastic hybrid component according to claim 1. The present invention therefore relates in particular to a method for repairing a damaged area of ​​a metal-plastic hybrid component of a structural assembly, wherein the plastic hybrid component has at least one reinforcement section comprising a reinforcement element, and the method comprises cutting the structural assembly at defined separation lines in such a way that openings are created in the structural assembly into which prefabricated replacement parts can be inserted which are faithfully reproduced in shape from the basic structural elements of the structural assembly.

[0002] Structural profiles and entire structural assemblies in vehicles, as well as in aircraft construction, are increasingly made of fiber-reinforced composite materials. Generally, there is a drive in vehicle construction to use lightweight yet high-strength structures that can withstand the expected loads. However, it frequently happens that such structures are damaged at exposed locations, particularly load-bearing areas such as the A- or B-pillars of the body, and consequently require repair. For example, EP 0 561 800 B1 discloses a method in which a damaged longitudinal member is separated from a node element at its connection point and replaced with a new member. The new member is fastened to the gusset plate by bolts that pass through both the flange of the node element and the new member, using an inserted nut plate.However, such established repair solutions offer advantages primarily for aluminum alloys and metal profiles, as they avoid the strength loss in the weld zone associated with fusion welding. US Patent 00 / 5281454 A discloses a method in which structural components are chamfered using corresponding surfaces so that they can then be rejoined using an adhesive between these surfaces. However, the methods known in the prior art cannot be readily transferred to hybrid components or entire hybrid structures.

[0003] To meet the increasing demands of industry for greater cost efficiency, functional integration, and new technologies, hybrid components are becoming increasingly prevalent in plastics engineering. Hybrid components, as defined in the present invention, are composite-reinforced metallic structures made of metal and plastic. Hybrid components are therefore typically smaller, lighter, more compact, and offer a wealth of advantages. Particularly in design and production, hybrid metal-plastic components are more advantageous than purely metal parts. Furthermore, plastic can be more easily formed into the desired shape. A hybrid component as defined in the present invention consists of at least two different materials that are functionally combined, thus jointly achieving an optimum of the new properties of the interconnected individual components.Wherever inherent contradictions exist regarding the properties of a single material, combining several different materials—i.e., hybrid components—provides a solution tailored to the specific application. Hybrid components can therefore be both soft and stiff, yet extremely strong and lightweight. The use of hybrid components is gaining importance, particularly in the automotive industry, where reducing fuel consumption and complying with environmental regulations remain ongoing technical challenges.

[0004] As previously explained, there is a need for a cost-effective and efficient repair of damaged structural components on a vehicle that consists of a structural assembly.

[0005] Even the repair methods known in the prior art for CFRP composites cannot be transferred to hybrid structures. Therefore, there are hardly any efficient repair concepts available for repairing hybrid structures at all.

[0006] Furthermore, it is not practical to implement the know-how required for repairing hybrid structures into repair workshops worldwide in order to repair damaged hybrid profiles according to a uniform quality standard.

[0007] Furthermore, the manual procedures and individual adjustments to the bodywork being repaired are expensive, time-consuming, and require a large number of spare parts.

[0008] Other repair methods known from the prior art, such as the use of screwable sleeves, dopplers or backing plates, cannot simply be transferred to the hybrid component designs used in practice.

[0009] Against this background, the object of the present invention is to overcome the aforementioned disadvantages and, in particular, to provide a cost-effective and universal solution for the repair of hybrid structures, which is also adaptable in local repair shops according to a reproducible standard.

[0010] This problem is solved by a method having the features of claim 1 and a set of spare parts according to claim 9.

[0011] The basic idea of ​​the present invention is to provide a structural assembly made of plastic hybrid components, which have reinforcement sections, with defined (imaginary) separation lines in the area of ​​the reinforcement sections, so that, in order to repair a damaged area of ​​the structural assembly, the damaged area can be cut out along a first and second adjacent separation line and a replacement part from the set of existing replacement parts, which is provided to fit the cut-out opening, can be provided.

[0012] Another aspect of the present invention is that a set of prefabricated replacement parts is provided in the assembly, corresponding to the number of resulting shapes between each pair of adjacent parting lines. This makes it possible to remove the damaged component along two adjacent parting lines and join it using a prefabricated replacement part in a suitable joining process. This reduces the number of parts and thus the number of components. It also allows the reinforcement section to be used simultaneously as a connecting element, coupling, or sleeve in the event of a repair. For this to be possible, the parting lines between the components must be positioned appropriately so that the individual parts can be replaced easily and cost-effectively.The position of the defined separation lines is determined by the corresponding frequency and probability of damage to the structural assembly. By integrating the repair function into the reinforcing fiber composite component, the number of parts required for repair can be reduced.

[0013] According to the invention, a method for repairing a damaged area of ​​the metal-plastic hybrid component of a structural assembly is therefore provided, wherein the plastic hybrid component has at least one reinforcement section comprising a reinforcement element and wherein the method comprises the following steps: a) Cutting through the plastic hybrid component above and below the damaged area along a first and second defined separation line through a reinforcement section each, b) Removal of the detached component section, c) Providing and inserting a precisely fitting replacement part into the opening of the separated plastic hybrid component, d) Connecting the replacement part to the plastic hybrid component at or adjacent to the separation lines, and e) Attaching one prefabricated reinforcement element in each area of ​​the respective reinforcement section.

[0014] In an advantageous embodiment of the invention, the plastic hybrid replacement part thus has a carbon fiber reinforced reinforcement element at at least one end, preferably at both ends, in order to reconnect it there to the severed structural assembly.

[0015] In a preferred embodiment of the invention, the plastic hybrid component has a carbon fiber reinforced reinforcement element as a reinforcement element in the area of ​​the reinforcement section(s).

[0016] In a further preferred embodiment of the invention, the separation lines are provided as predefined imaginary lines on the assembly, whereby a predetermined opening is created between the separation lines after cutting along the separation line. In this way, it is ensured that the entire assembly can be reproducibly repaired on-site. The assembly is separated precisely along the defined separation lines, and the damaged component or the detached component section is removed, while a replacement part of identical shape is inserted.

[0017] It is particularly advantageous that by cutting through the plastic hybrid component above and below the damaged area in the region of the reinforcement element, upper and lower connection contours corresponding to a prefabricated replacement part are created on the assembly. This makes it possible to mold a prefabricated, precisely fitting replacement part into the opening of the cut plastic hybrid component, forming both the upper and lower connection contours.

[0018] In a particularly advantageous embodiment of the invention, the assembly has a plurality of pairs of imaginary adjacent dividing lines. It is further preferred that a component section is provided in the assembly between each pair of dividing lines of two adjacent dividing lines, and that a replacement part corresponding in its respective form is available or provided.

[0019] In this way it is possible to repair a large number of exposed areas on the structural assembly according to the inventive method by cutting through the corresponding reinforcement sections along adjacent separation lines.

[0020] It is therefore particularly advantageous if the separation lines are located in areas with a reinforcing element. In this way, the reinforcing fiber composite component can simultaneously be used as a connecting element.

[0021] It is further advantageous if the replacement part is joined to the assembly, particularly along the connection contour, by means of welding, gluing, riveting or stapling.

[0022] Another aspect of the present invention is the provision of precisely fitting replacement parts. According to the invention, a set of prefabricated replacement parts is provided, corresponding to the number of molds between each pair of adjacent parting lines of the assembly. In this way, damage in the corresponding sections between any two adjacent pairs of parting lines can be repaired by an available replacement part. It is particularly advantageous if the replacement parts themselves are at least partially carbon fiber reinforced composite components or carbon fiber reinforced hybrid components.

[0023] Other advantageous embodiments of the invention are specified in the dependent claims or are explained in more detail below with reference to the figures, together with the description of preferred embodiments of the invention. The figures show: Fig. 1. An exemplary view of a construction assembly; Fig. 2 a detail of the construction assembly designed as a plastic hybrid component; Fig. 3 a perfectly fitting, exemplary replacement part for insertion between the two cutting lines made of Fig. 2.

[0024] In Fig. Figure 1 shows an exemplary assembly 3 in the form of a vehicle body. In the vehicle body shown here, assembly 3 consists of several plastic hybrid components 1. Based on the in Fig. 2 exemplary B-pillars of the structural assembly made of Fig. 1. The method according to the invention will be explained in more detail. In the assembly shown in Section 1. Fig. Figure 1 further shows defined separation lines 6, 6', at which separation cuts are intended to be made when repairing the component sections 10, which lie between each adjacent separation cut along the separation lines 6, 6'. According to the method according to the invention, in the detailed view of the Fig. 2. The B-pillar is cut through at the first (upper) dividing line 6 in the area of ​​the reinforcement section 5, in which a carbon fiber reinforcement element 4 is arranged. At a second (lower) dividing line 6', the plastic hybrid component 1 is also cut through, so that the damaged area 2 between the two dividing lines 6, 6' can be removed.

[0025] To accomplish this, the separated component section 10, which results between the two separation lines 6 and 6', is cut out or removed. This creates an opening in the assembly 3 between the upper separation line 6 and the lower separation line 6'. A prefabricated replacement part 10', as shown in the example in Fig. Figure 3 shows the following: It is evident that the upper and lower connection contours 7, 7' on the assembly 3 correspond to the upper and lower connection contours 7, 7' on the replacement part 10'. After inserting the precisely fitting replacement part 10', it can be connected to the assembly 3 with the plastic hybrid component at or adjacent to the parting lines 6, 6'. A prefabricated reinforcement element 4 can be applied in the area of ​​the respective reinforcement section 5, or the existing reinforcement element 4 can be used or reused as a kind of overlapping patch. In the present example, according to... Fig. Figure 2 indicates the CFRP reinforcement is located on the outside. However, it is preferably installed on the inside.

[0026] The invention is not limited in its implementation to the preferred embodiments specified above. Rather, a number of variants are conceivable which utilize the solution presented, even with a fundamentally different design.

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