Hybrid structure and manufacturing method

Abstract

To provide a hybrid reinforcement member for reinforcing a portion of a vehicle body frame.SOLUTION: The invention relates to a hybrid structure, the 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 to the first component, the second component having a reinforcing portion for structurally reinforcing the first component and which extends longitudinally of and within the first component, and the thermoplastic second component further having a lock securing portion extending adjacent and over at least a portion of an exterior surface of the first component, and the reinforcing portion and the lock securing portion are integrally formed with the thermoplastic second component, thereby interlocking the first component within the thermoplastic second component. The invention likewise relates to a method for producing such a hybrid structure and to a vehicle equipped with such a hybrid structure.SELECTED DRAWING: Figure 2a

Description

[Technical field]

[0001] The present invention relates to a hybrid structure, in particular to a hybrid reinforcement member for reinforcing a portion of a body frame of a vehicle. Furthermore, the present invention relates to a method for manufacturing such a hybrid structure. Still further, the present invention relates to a vehicle equipped with such a hybrid structure. [Background technology]

[0002] Engineered systems in today's automobiles are often designed and built to meet complex, conflicting requirements. Although mobility is the primary function of an automobile, achieving it in an energy-efficient manner and ensuring occupant safety are critical requirements. Automotive OEMs are therefore actively striving to make vehicles lighter without compromising vehicle safety. Meeting such combined requirements often requires solutions that encompass innovative designs, manufacturing processes, and multi-material systems.

[0003] Hybrid systems or structures combining various different materials are increasingly used throughout the automotive industry because they are significantly lighter than mono-material systems, by more than two times, and exhibit very good properties in terms of safety. Furthermore, hybrid structures are known to offer significant cost advantages through part integration and cycle time reduction. Generally, in metal-plastic or composite-plastic hybrid systems, there is a metal or composite structure operating throughout the primary load transfer path, and a secondary plastic structure is bonded to the metal or composite structure to improve the local stiffness of the assembly. Generally, hybrid systems help reduce weight by up to 50% compared to mono-material systems while maintaining the desired performance.

[0004] For example, US Pat. No. 5,399,633 discloses interlocking of a profile member with a reinforcement member by forcing a polymeric material into the wall edge or into an opening between two wall edges. The wall edges act as flow fronts, similar to runners, to carry the melt throughout the profile member. During injection molding, the plastic fills the channels forming a mechanical, interlocking connection between both materials to form a hybrid structure.

[0005] The use of dissimilar materials within a system requires bonding between the two dissimilar materials, which can be inherently difficult to overcome. Several bonding techniques have been used, such as mechanical bonding between the metal of the composite structure and the secondary structure, or chemical and / or laser treatment of the metal or composite structure prior to molding the secondary plastic structure onto its surface. The use of adhesives is yet another method used across industries to improve bond formation between dissimilar materials.

[0006] In view of the above, it would be desirable to provide a hybrid component with connections between dissimilar materials that alleviates at least some of the perceived inconveniences of the prior art. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] US Patent Application Publication No. 2008 / 0138586 Summary of the Invention [Means for solving the problem]

[0008] In accordance with the present invention, a hybrid structure is provided comprising: a first component having a base and an upstanding wall extending from the base, the first component having an interior enclosed between the upstanding wall and the base; and a thermoplastic second component molded over the first component, the second component comprising a reinforcing portion for structurally reinforcing the first component, the reinforcing portion extending longitudinally of the first component and being interior to the first component, the second thermoplastic component further comprising a locking portion extending adjacently over at least a portion of an outer surface of the first component, the reinforcing portion and the locking portion being integrally formed thereby interlocking the first component within the second thermoplastic component.

[0009] Establishing a connection between two components of dissimilar materials that can withstand the mechanical performance requirements for the automotive industry or any other industry where safety is critical is a challenge. Hybrid structures as described herein provide a cost-effective solution for joining dissimilar materials by creating a mechanical locking fastener via (partial) encapsulation of a preformed first component inside a thermoplastic second component.

[0010] The thermoplastic second component locks to the first component by enclosing it between a reinforcing portion of the first component and a locking portion adjacent to the outer surface of the first component and connected to the reinforcing portion. This locking of the first component may be by complete enclosing, i.e. the first component is completely encapsulated inside the second component, or by partial enclosing, i.e. parts of the first component are not covered by or free from the second component. By locking the first component inside the second component, a mechanical bond is created between the first and second components without the use of adhesives. The hybrid structure may form a single integral member with good structural integrity. The hybrid structure makes it possible to obtain complex geometries that were otherwise difficult to achieve using only metals or composites.

[0011] According to one embodiment, the first component comprises at least one through hole, and the locking portion connects to the reinforcement portion through the through hole. The through hole may be in the base and / or the upstanding wall of the first component.

[0012] To additionally secure the second component to the first component, the first component may include at least one through hole extending from an outer surface of the first component to an interior of the first component. The locking portion of the second component extends over and into the through hole. The portion of the locking portion that extends into the through hole may be connected to or integrally formed with the reinforcing portion of the second component.

[0013] The first component may have at least two opposing upstanding walls extending from a base such that an interior of the first component forms a channel. The reinforcing portion may then be within the channel. The reinforcing portion may extend between opposing sides of the channel.

[0014] The reinforcing portion may extend toward and be adjacent to the base of the first component, thereby filling the space enclosed by the base and the upstanding wall(s) of the first component. Preferably, the reinforcing portion comprises an open structure, e.g., an alveolar structure with channels oriented transversely to the base of the first component. Hybrid structures may have alveolar structures, more commonly referred to as "honeycombs" (e.g., arrays of columns and channels). The combs of the structure may be any polygonal or round shape, such as circular, elliptical, square, rectangular, triangular, rhomboidal, pentagonal, hexagonal, heptagonal and octagonal geometries, as well as combinations comprising at least one of the aforementioned geometries. The plastic honeycomb may be made by molding a plastic honeycomb into the first component.

[0015] Where the first component has at least two opposing upstanding walls with end edges, the reinforcing portion may extend from one end edge to the opposing end edge of the first component. Preferably, the locking portion extends on the outer surface of the first component from one end edge to the opposing end edge of the first component, so as to connect with the reinforcing portion at the end edge of the first component.

[0016] The locking portion may be formed as a ribbon-shaped locking member. The locking portion may extend in a ribbon-like manner on the outer surface of the first component, thereby partially covering the outer surface of the first component. Preferably, the ribbon-like locking member may extend from one side of the second component on the outer surface of the first component to an opposite side of the second component, thereby partially covering the outer surface of the first component. Preferably, two or more ribbon-like locking members extend on the first component, possibly at a distance different from zero from each other. Preferably, the ribbon-like locking members cover less than 75 percent (or less than 50 percent, e.g. less than 30 percent) of the outer surface 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 comprise a frame molded onto the end edges of the first component that partially covers the outer surface of the first component, thereby surrounding and enclosing the end edges of the first component.

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

[0019] According to a further embodiment, the base and / or the upright walls are provided on their outer surface with undulations extending in the longitudinal direction of the first component. Preferably, the locking portion adjacent the outer surface of the first component extends with the longitudinal undulations. The undulations may be recesses or ridges relative to the base and / or the upright walls of the first component.

[0020] The locking portion may extend along a portion of the undulation, either continuously or intermittently. The undulation may have a length less than or equal to the length of the first component. The undulation may comprise a portion that branches off at an angle differing from the longitudinal undulation by 0 or 180 degrees, such that an undulating branch is formed. Preferably, the locking portion extends over or within the undulating branch as well.

[0021] The base of the first component may have a number of through holes through which the locking portion extends to the outer surface of the first component. Preferably, the through holes provided in the base are at or within the undulations, and at least one through hole is provided for each undulation branch, such that the locking portion connects with reinforcing portions in the first component at various positions along the undulations, thereby enhancing the mechanical interlocking between the first and second components.

[0022] Additionally or alternatively, the base and / or upstanding walls of the first component may include an internal undulation, and the second component may extend with a longitudinal undulation. The undulation may be a recess or a protuberance relative to the base and / or upstanding walls of the first component.

[0023] The internal undulations of the first component may form flow fronts of the thermoplastic material when the second component is molded onto the first component, which is particularly advantageous when the reinforcing portion has an alveolar structure, so that the flow fronts may direct the flow of the thermoplastic material into the mold for the alveolar structure in a relatively faster and more efficient manner.

[0024] The base of the first component may have an offset or undulation that forms either a depression on the outer surface of the first component and a raised portion on the interior of the first component, or a raised portion on the outer surface of the first component and a depression on the interior of the first component. Preferably, the undulation of the base on the interior of the first component is the negative of the undulation on the outer surface of the base of the first component.

[0025] Alternatively or additionally, undulations are provided in the upstanding walls of the first component, the undulations extending in the longitudinal direction of the first component, such undulations providing additional strength to the first component.

[0026] According to further embodiments, the first component may be a composite component, a metallic component or a composite / metallic hybrid component. Furthermore, the first component may be made of a thermoset or a thermoplastic material, the thermoplastic material of the first component having a higher thermal stability and / or a higher flow temperature compared to the thermoplastic material of the second component.

[0027] Some possible metal component materials include aluminum, titanium, chromium, magnesium, zinc and steel, as well as combinations or alloys that include at least one of the aforementioned materials. The wall thickness of the metal component may be continuous for all walls or may vary along the first component to improve stiffness in a desired direction. For example, one of the opposing walls may have a greater / lesser thickness than the other of the opposing walls. In some embodiments, the metal component has a wall thickness of 1.6 millimeters (mm) or less, particularly between 1.0 mm and 1.5 mm, and more particularly between 1.3 mm and 1.4 mm. Typically, the walls of the metal component have a wall thickness of more than 1.8 mm for the entire metal structure. Thus, the use of plastic reinforcements allows for a reduction in wall thickness of 10% or more, particularly between 20% or more, and even more particularly between 25% or more.

[0028] Possible composite materials are combinations of plastic matrix materials, either thermoplastic or thermosetting, with reinforcing filler materials. Examples of such filler materials may include fibers, long or continuous fibers, or non-woven or woven fabrics of continuous fibers. The composite materials may comprise at least one of glass, carbon and aramid fibers, respectively. Another possibility is less commonly used metal fibers, such as boron-tungsten fibers and silicon carbide coated fibers, or ceramic fibers, such as quartz, silica or alumina fibers. Examples of thermosetting materials may include 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, phenylene 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™ resin, which is commercially available from SABIC. The plastic may be optionally reinforced, for example, by fibers, particles, flakes, and combinations including at least one of the foregoing. For example, the thermoplastic second component may be formed from STAMAX™ material, a long glass fiber reinforced polypropylene commercially available from SABIC. The thermoplastic second component may also be made from combinations including at least one of any of the above materials and / or reinforcements.

[0030] Additionally, the characteristics of the second component will be based on the energy absorption properties desired in a particular area, such as the number of combs per unit area, the thickness of the comb walls, and the particular material of the reinforcement section. The density of the combs (number of combs per unit area) depends on the desired stiffness and the materials used. In some embodiments, the density is 100 mm 2 (mm 3 ). 2 1 to 20 combs per 100mm 2 1-10 combs per 100mm 2 In various embodiments, the wall thickness of the reinforcement portion may be from 0.5 mm to 10 mm, particularly from 2 mm to 5 mm, and more particularly from 2.5 mm to 4 mm.

[0031] The second component may have a length equal to or less than the length of the first component (e.g., may be localized, i.e., disposed only in a specific location to enhance structural integrity at that location). Desirably, to maximize weight savings, the second component is positioned to add the least amount of weight necessary to achieve the desired structural integrity (e.g., structural integrity that is equal to or greater than a standard metal component that does not have thinner walls). In various embodiments, the length of the second component may be 80% or less of the length of the first component, specifically 60% or less, more specifically 50% or less, and even more specifically 10% to 35% of the length of the first component.

[0032] Preferably, the hybrid structure is a reinforcing member for the body frame of the vehicle. To be able to connect the hybrid structure as a stiffening or reinforcing part to the body frame of the vehicle, the outer surface of the first component may comprise a connection area free from the second component such that the hybrid structure is connectable to the body frame of the vehicle. In this way, the hybrid structure may be left unmolded in selective locations thereon that are used to join the member with the body frame. Preferably, the hybrid structure is connectable to the body frame of the vehicle by at least one of mechanical fasteners, welding and adhesives, or any similar joining method.

[0033] The present invention also relates to a vehicle comprising such a hybrid structure. The hybrid structure may be configured to stiffen a portion of the vehicle's body frame, for example a body-in-white frame for a motorized vehicle such as an automobile. Furthermore, the hybrid structure may be a stiffener member for one of the A-pillar, B-pillar, C-pillar, D-pillar regions and a roof pillar of the vehicle's body frame, or a portion of one of them. Alternatively, the hybrid structure may be used to form the entire body-in-white or structural body frame of the vehicle. Other applications of the hybrid structure in a vehicle may be for tailgates, seat frames, bumper beams or other energy absorbing components, front-end modules, battery carriers, cross car beams, and any other structural vehicle components for which a hybrid structure as described herein is beneficial and / or suitable.

[0034] Various weight reduction opportunities may be achieved using hybrid structures, either by replacing existing metal reinforcements in the white frame body or by replacing complete subsystems such as B-pillars. For example, a combination of high heat unfilled thermoplastics (high toughness and ductility) or fiber reinforced thermoplastics (high stiffness and strength) with metals is appropriately selected based on the requirements. For example, unfilled thermoplastics resin molded with multiple metal inserts may be used to replace the energy absorbing members that are duty-bound in the floor rocker for side impacts, and fiber blended thermoplastics overmolded with metal inserts are selected to replace the existing B-pillars with equivalent crash performance. The hybrid structure designed as the B-pillar may replace a multi-part B-pillar made of high tensile steel. Metal inserts or components in the hybrid structure may be exploited for ease of assembly in the white frame body. Such a solution not only provides part integration possibilities with equivalent crash performance as that of a common vehicle, but also gives the opportunity to replace the high tensile steels currently used in the white frame body with medium strength steels, 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 regions, and a roof pillar of the body-in-white frame of the vehicle.

[0036] The present invention further relates to a method for manufacturing such a hybrid structure, the method comprising: 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 an outer surface of the first component to cover at least a portion of the outer surface, the reinforcing portion and the locking portion being integrally molded, thereby interlocking the second component with the first component.

[0037] For the method, a tooling or mold or cast having a cavity and a core may be used. A first component may be provided in the cavity and the core is inserted into the interior of the first component. The cavity and core may be shaped to allow a thermoplastic material to flow inside the first component to form the reinforcement portion and over an exterior surface of the first component to form the locking portion. The first component is then overmolded with the thermoplastic material to form a thermoplastic second component.

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

[0039] According to an 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 includes molding the second component through the through hole to form the reinforcing portion or the locking portion.

[0040] The through holes may be provided in the base and / or the upstanding walls and allow the thermoplastic material to flow between the interior and exterior surface of the first component, and upon solidification of the thermoplastic material, the material of the through holes connects the reinforcing portion on the interior of the first component and the locking portion on the exterior surface of the first component.

[0041] Alternatively or additionally, the first component may have at least two opposing upstanding walls having end edges, and the method further includes molding a reinforcing portion on an interior of the first component from one end edge to an opposing end edge, and molding a locking portion on an exterior surface of the first component from one end edge to an opposing end edge of the first component, thereby connecting the locking portion with 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 an outer surface 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 appreciated with reference to the following figures of several exemplary embodiments. [Figure 1a] In the various figures, hybrid structures according to embodiments of the present invention are shown. [Figure 1b] In the various figures, hybrid structures according to embodiments of the present invention are shown. [Figure 1c] In the various figures, hybrid structures according to embodiments of the present invention are shown. [Figure 2a]1 shows the separate components of the hybrid structure of FIGS. 1a-1c. [Figure 2b] 1 shows the separate components of the hybrid structure of FIGS. 1a-1c. [Figure 2c] 1 shows the separate components of the hybrid structure of FIGS. 1a-1c. [Figure 3a] 4 shows a hybrid structure according to a second embodiment of the present invention. [Figure 3b] 4 shows a hybrid structure according to a second embodiment of the present invention. [Figure 4a] 4 shows a hybrid structure according to a third embodiment of the present invention. [Figure 4b] 4 shows a hybrid structure according to a third embodiment of the present invention. [Diagram 5] FIG. 5 is a plan view of the exterior surface of the first component of the hybrid structure of FIGS. 3 and 4. [Figure 6] FIG. 5 is a bottom view of the interior of the hybrid structure of FIGS. 3 and 4. [Figure 7a] 1 shows a hybrid structure according to a fourth embodiment of the present invention. [Figure 7b] 1 shows a hybrid structure according to a fourth embodiment of the present invention. [Figure 7c] 1 shows a hybrid structure according to a fourth embodiment of the present invention. [Figure 8] 1 shows parts of an automobile's structural body frame. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0044] Figure 1a shows a plan view of an embodiment of a hybrid structure 100 according to the invention. The hybrid structure 100 comprises a first component 110 and a thermoplastic second component 120. The first component has a base 111 and two opposing upstanding walls 112 extending from the base 111 (see also Figure 2c). The base 111 has a number of through holes 113 (see Figure 2c). The upstanding walls 112 have a number 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.

[0045] The second component 120 is made of a thermoplastic material that is molded onto the first component 110. The second component 120 has a reinforcing portion 121 that structurally reinforces the first component 110. The reinforcing portion 121 is inside the channel shape and extends in the longitudinal direction of the channel between the opposing walls 112 of the first component 110. The thermoplastic second component 120 further comprises a locking portion 124 adjacent to the outer surface 115 of the first component 110. The locking portion 124 comprises a ribbon-like locking portion 125 that extends adjacently over a portion of the outer surface 115 of the first component 110, i.e. that covers a portion of the outer surface 115 of the first component 110. The ribbon-like locking portion 115 connects with the reinforcing portion 121 through a through hole 113 in the base 111 and a further through hole 116 in the upstanding wall 112 of the first component 110. By extending into the through holes 113, 116 and on the outer surface 115, the second component 120 thereby interlocks with the first component 110. Referring to Fig. 1c and Fig. 2a, the locking portion 124 further comprises a frame 126 molded on the end edge 117 of the first component 110. The frame 126 encases the upright wall 112 of the first component and the terminal edge 117 of the first component 110 at each free end. The frame 126 is adjacent to a portion of the outer surface 115 of the first component 110. The ribbon-like locking portion 125 is connected to the frame 126 at the end edge 117 of the first component 110 at the upright wall 112, thereby forming the second component 120 of one-piece shape molded on the first component 110.

[0046] The reinforcing portion 121 is formed as an open cell structure, shown in FIG. 1b as being shaped like a honeycomb. The honeycomb structure forms channels 122 with an axial direction toward the base 111 of the first component 110. For the embodiment shown, the channels 122 of the honeycomb structure are oriented perpendicular to the longitudinal direction of the first component 110. Alternatively, the axial direction of the honeycomb channels may form an angle of more than 0 degrees and less than 90 degrees, or more than 90 degrees and less than 180 degrees, with the longitudinal direction of the first component 110 or its base 111. FIG. 2b shows that the walls 123 of the honeycomb structure extend from the base 111 to the end edge 101 of the hybrid structure 100, and thus extend beyond the height of the hybrid structure. Alternatively, the walls 123 of the honeycomb structure may extend from the base 111 to the end edge 117 of the first component 110.

[0047] 3a and 3b show a hybrid structure 200 according to a second embodiment of the invention. The hybrid structure 200 comprises a first component 210 and a thermoplastic second component 220. The first component comprises a base 211 and two opposing upright walls 212 extending from the base 211. The base 211 comprises a number of through holes (see FIG. 5). The upright walls 212 comprise a number of further through holes (see FIG. 5), which are aligned with the through holes of the base 211. The first component 210 has an interior 214 formed as a channel, as shown in FIG. 2c. The base 211 of the first component 210 comprises undulations formed as recesses 218 on its outer surface 215. The base 211 of the first component 210 comprises raised portions (not shown) on its inner surface 214, which are the negative shape of the recesses 218 on the outer surface 215. 5, the recess 218 comprises a branch 218a that extends perpendicularly from the recess 218 in the base 211 towards an end edge 217 of the upstanding wall 212 of the first component 210. The recess branch 218a has an end at a non-zero distance from the end edge 217, i.e. the branch 218a does not extend all the way to the end edge 217 but terminates at a non-zero distance from the end edge 217. Alternatively, the branch terminates at the end edge.

[0048] 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 210. The reinforcing portion 221 is in the channel and extends longitudinally between the opposing walls 212 of the first component 210. The thermoplastic second component 220 further comprises a locking portion 224 that is provided adjacent to the outer surface 215 of the first component 210 in a recess 218 and its branch 218a in the outer surface 215 of the first component 210, thereby forming an interrupted ribbon-like locking portion 225 in the recess 218 and its branch 218a. The upper surface of the ribbon-like locking portion 225 is flush with the outer surface of the first component 210. The ribbon-like locking fastener 225 connects the locking fastener part 224 with the reinforcement part 221 through a through hole in the base part 211 and a further through hole in the upright wall 212 of the first component 210. By extending into the through hole (not shown) and on the outer surface 215, the second component 220 interlocks with the first component 210. The locking fastener part 224 further comprises a frame 226, see FIG. 3a, which is molded on the end edge of the first component 210. The frame 226 encases 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 outer surface 215 of the first component 210. The ribbon-like locking fastener 225 of this second embodiment of the hybrid structure does not connect to the frame 226.

[0049] FIG. 3b shows only the second component 220 of the hybrid structure 200, i.e. the thermoplastic portion of the hybrid structure 200. The second component 220 is formed inside the first component 210 in an adjacent portion 229 forming the base portion of the second component 220, partially covering the base 211. In FIG. 3b, the reinforcing portion 221 is formed as an open alveolar structure shown to be shaped like a honeycomb. The honeycomb structure forms channels 222 having an axial direction A. In the hybrid structure, the axial direction A faces towards the base 211 of the first component 210. For the embodiment shown, the channels of the honeycomb structure are oriented perpendicular to the longitudinal direction of the first component. FIG. 3b shows that the adjacent portion 229 includes walls 223 of the honeycomb structure, which extend from the base 211 to the end edge 201 of the hybrid structure 200. Alternatively, the walls of the honeycomb structure may extend from the base to the end edge of the first component, or between the base (but not so adjacent) and the end edge, so as not to extend completely beyond the height of the first component or hybrid structure.

[0050] Figure 3b shows a flow tip 227 that is shaped according to a raised portion (not shown in Figure 3a) that is the negative shape of the recess 218 shown in Figure 3a. The flow tip 227 in Figure 3b is formed as a trough that extends longitudinally and continuously on the second component 220 and connects at each end with a frame 226 at the free end of the first component 210.

[0051] 4a and 4b show a hybrid structure 300 according to a third embodiment of the invention. The hybrid structure 300 comprises a first component 310 and a thermoplastic second component 320. The first component comprises a base 311 and two opposing upright walls 312 extending from the base 311. The base 311 comprises a number of through holes (see FIG. 5). The upright walls 312 comprise a number of further through holes (see FIG. 5), which are aligned with the through holes of the base 311. The first component 310 has an interior 314 formed as a channel. The base 311 of the first component 310 comprises undulations formed as recesses 318 on its outer surface 315. The base 311 of the first component 310 comprises raised portions (not shown) on its inner surface 314, which are the negative shape of the recesses 318 on the outer surface 315. The recess 318 comprises a branch (318a) that extends perpendicularly from the recess 318 in the base 311 towards an end edge 317 of the upstanding wall 312 of the first component 310 (see FIG. 5 ). The recess branch 318a has an end at a non-zero distance from the end edge 317, i.e., the branch 318a does not extend all the way to the end edge 317, but terminates at a non-zero distance from the end edge 317.

[0052] The second component 320 is made of a thermoplastic material molded to the first component 310. The second component 320 has a reinforcing portion 321 that structurally reinforces the first component 310. The reinforcing portion 321 is inside the first component and extends in the longitudinal direction of the channel between the opposing walls 312 of the first component 310. The thermoplastic second component 320 further comprises a locking portion 324 adjacent to the outer surface 315 of the first component 310 and provided in a recess 318 in the outer surface 315 of the first component 310 and its branches, thereby forming an interrupted ribbon-like locking portion 325 in the recess 318. The ribbon-like locking portion 325 connects the locking portion 324 with the reinforcing portion 321 through a through hole in the base 311 and a further through hole in the upright wall 312 of the first component 310. By extending into the through holes 313, 316 and on the outer surface 315, the second component 320 interlocks with the first component 310. The locking fixing part 324 further includes a frame 326 molded on the end edge (see FIG. 5) of the first component 310. The ribbon-like locking fixing part 325 extends transversely within the branch and further towards the frame 326. The ribbon-like locking fixing part 325 of this third embodiment of the hybrid structure is thereby connected to the frame 326. The ribbon-like locking fixing part 325 has a part provided within the branch 318a of the recess 318 in the upright wall 312 and a second part covering the outer surface 315 of the first component 310 and connecting to the frame 326.

[0053] Figure 4b shows the second component 320 of the hybrid structure 300. That is, only the thermoplastic portion of the hybrid structure 300 is shown in Figure 4b. The second component 320 is formed to completely cover the base 311 of the first component 310, with the adjacent portion 329 forming the base of the second component 320.

[0054] Figure 5 is a plan view of the outer surface of the first component 210,310 of the hybrid structure of Figures 3 and 4. 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 number of through holes 213,313. The upright walls 212,312 have a number of further through holes 216,316 which are aligned with the through holes 213,313 of the base 211,311. At its outer surface 215,315, the base 211,311 of the first component 210,310 is provided with reliefs formed as recesses 218,318. Inside it, the base of the first component comprises a raised portion (not shown) which is the negative shape of the recess 218, 318 in the outer surface 215, 315. The recess 218, 318 comprises a branch 218a, 318a which extends perpendicularly from the recess 218, 318 in the base 211, 311 towards the end edge 217, 317 of the upstanding wall 212, 312 of the first component 210, 310. The recess branch 218a, 318a terminates at a non-zero distance from the end edge 217, 317, i.e. the branch 218a, 318a does not extend up to the end edge 217, 317 but terminates at a non-zero distance from the end edge 217, 317.

[0055] FIG. 5 further shows that at the free ends of each of the interrupted ribbon-like lock fasteners 225,325 in the recesses, through holes 213,313,216,316 are provided so that the ends of each of the ribbon-like lock fasteners 225,325 connect to the reinforcing portions 221,321.

[0056] FIG. 6 is a bottom view of the interior 214, 314 of the hybrid structure 200, 300 of FIGS. 3 and 4. A reinforcing portion 221, 321 of the second component 220, 320 is formed in the interior 214, 314 of the first component 210, 310. The reinforcing portion 221, 321 has an open cell structure shown to be shaped like a honeycomb in FIG. 6. Referring also to FIG. 3b, the honeycomb structure forms channels 222, 322 with an axial direction A. In the hybrid structure 200, 300, the axial direction A faces towards the base 211, 311 of the first component 210, 310. FIG. 6 shows a flow tip 227, 327 that follows the shape of the raised portion 219, 319, which is the negative shape of the recess 218, 318 shown in FIG. 5. The flow tip 227 in FIG. 6 is shaped like a trough that extends continuously longitudinally on the second component 220,320 and connects at each end with a frame 226,326 at the free end of the first component 210,310.

[0057] 7a-7c show a hybrid structure 400 according to a fourth embodiment of the invention. The hybrid structure 400 comprises a first component 410 and a thermoplastic second component 420, which extends in the longitudinal direction of the first component 410 from an upright wall 412 and a base 411. The first and second components then extend in a parallel manner. The second component 420 comprises a reinforcing portion 421 and a further upright wall 428, which delimits the second component 420 and delimits the reinforcing portion 421 in the transverse direction. The reinforcing portion 421 has a honeycomb-shaped cell structure with channels 422 with an axial direction A perpendicular to the base 411 of the first component. The channels 422 are delimited by cell walls 423.

[0058] Referring to Fig. 7b, a raised portion 419 runs longitudinally along the base 411 of the first component. The raised portion 419 has a vertical branch 419a. Within the raised portion 419 and its branch 419a, a plurality of through holes 413, 416 are provided, each at a distance from another through hole. Fig. 7a shows that the longitudinally extending raised portion 419 is covered by the thermoplastic material of the second component 420.

[0059] 7c shows that the outer surface 415 of the first component 410 is provided with a recess 418 having a vertical branch 418a. The recess 418 and the vertical recess branch 418a are the negative shape of the raised portion 419 and the raised portion branch 419a on the inner portion 414 of the first component 410, and vice versa. The through holes 413, 416 extend from the inner portion 414 of the first component 410 to the outer surface 416, and vice versa. The recess 418 and its branches are provided with interrupted and branched ribbon-like locking portions 425 of the locking portion 424 to lock the first component 410 with the second component 420 to form the hybrid structure 400.

[0060] 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 upstanding walls 112, 212, 312, 412. The first component is then inserted into a cavity (not shown) of an injection molding tooling or cast or mold (not shown) that is configured to receive the first component 110, 210, 310, 410 with or without at least a portion of the frame portion 124, 224, 324, 424 and form a portion of the second component 120, 220, 320, 420, specifically the locking portion 124, 224, 324, 424. The injection moulding tooling is then closed by inserting the core into the interior 114, 214, 314, 414 of the first component 110, 210, 310, 410. The core is shaped to form the reinforcement portion 121, 221, 321, 421, in particular the alveolar or honeycomb structure of the reinforcement portion, and possibly at least a part of the frame 116, 216, 316. After closing the mould or cast, a flowable or molten thermoplastic material is injected into the tooling through an injection point. The raised portions 219, 319, 419 shown in figures 3-7 may be used as flow tips during the injection of the flowable thermoplastic material so that the material can more easily flow into the core to form the honeycomb cells. Upon cooling of the thermoplastic material, the second components 120,220,320,420 solidify and at least partially encapsulate the first components 110,210,310,410, thereby interlocking with one another, and the hybrid structure 100,200,300,400 is formed.

[0061] When the first component 110, 210, 310, 410 is made of a composite material, the pre-forming of the first component 110, 210, 310, 410 may be performed simultaneously with the injection molding of the second component 120, 220, 320, 420 in a single machine, which is known as an integrated manufacturing cell.

[0062] 8 shows a portion of a vehicle, more specifically, an automobile structural body frame 500. Hybrid structures may be in various areas of the vehicle, such as in the body-in-white (BIW, also known as black body), such as in the A-pillars 504, in the B-pillars 502, in the roof rails 503 and in the floor rockers 501, among others, and combinations including at least one of the foregoing.

[0063] The structural body frame comprises several hollow vehicle components such as A-pillars 504, B-pillars 502, roof rails 503 and floor rockers 501 and others that are welded or otherwise joined together. The hybrid structure 100, 200, 300, 400 may be used as a reinforcement for such hollow vehicle components inserted into spaces 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 may form the hollow vehicle components such as A-pillars 504, B-pillars 502, roof rails 503 and floor rockers 501 and others, and the second component 120, 220, 320, 420 is injection molded into this hollow vehicle component for reinforcement.

[0064] Some examples of hybrid structures are given below.

[0065] (Aspect 1) A hybrid structure comprising: a first component having a base and upstanding walls extending from the base (preferably at least two opposing upstanding walls extending from the base, preferably in the same direction from the base), the first component having an interior enclosed between the upstanding 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 longitudinally of the first component and within the first component, the thermoplastic second component further comprising a locking portion extending adjacently over at least a portion of an outer surface of the first component, the reinforcing portion and the locking portion being integrally formed, thereby interlocking the first component within the thermoplastic second component.

[0066] (Aspect 2) The hybrid structure of aspect 1, wherein the first component has a through hole, and the lock fixing portion connects to the reinforcement portion through the through hole.

[0067] (Aspect 3) A hybrid structure described in any of aspects 1-2, wherein the first component has at least two opposing upright walls having end edges, the reinforcing portion extends from one end edge to an opposing end edge of the first component, and the locking fixing portion extends on the outer surface of the first component from the one end edge to the opposing end edge of the first component, thereby connecting with the reinforcing portion at the end edge of the first component.

[0068] (Embodiment 4) A hybrid structure described in any of embodiments 1 to 3, wherein the first component has at least two opposing upright walls having end edges, and the locking fixing portion comprises a frame molded onto the end edges of the first component that partially covers the outer surface of the first component, thereby surrounding and wrapping the end edges of the first component.

[0069] (Aspect 5) A hybrid structure described in any of Aspects 1 to 4, wherein the reinforcing portion has an alveolar structure having channels oriented laterally relative to the base of the first component.

[0070] (Aspect 6) A hybrid structure described in any of aspects 1 to 5, wherein the base has an outer surface of the first component with an undulation extending in the longitudinal direction of the first component, and the lock fixing portion adjacent to the outer surface of the first component extends in the longitudinal direction together with the undulation.

[0071] (Aspect 7) The hybrid structure of any one of aspects 1 to 6, wherein the base has undulations within the first component, and the second component extends in the longitudinal direction together with the undulations.

[0072] (Aspect 8) The hybrid structure of any one of aspects 1 to 7, wherein the first component is a composite component, a metallic component, or a composite / metallic hybrid component.

[0073] (Aspect 9) The hybrid structure described in Aspect 8, wherein the hybrid structure is a reinforcement member for a vehicle body frame, and the reinforcement member is connectable to the body frame by at least one of mechanical fasteners, welding, and adhesives.

[0074] (Aspect 10) A vehicle equipped with the hybrid structure described in any one of aspects 1 to 9.

[0075] (Aspect 11) The vehicle described in Aspect 10, further comprising a structural body frame, the hybrid structure forming 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 regions and roof pillar of the vehicle's body-in-white frame.

[0076] (Aspect 12) A method for manufacturing a hybrid structure described in any of aspects 1 to 11, the method including the steps of providing the first component, and providing the thermoplastic second component to the first component by molding the reinforcing portion inside the first component and molding the locking portion on an outer surface of the first component to cover at least a portion of the outer surface, wherein the reinforcing portion and the locking portion are integrally molded, thereby interlocking the second component and the first component.

[0077] (Aspect 13) The method described in Aspect 12, wherein the base and / or the upright wall of the first component have a through hole, and the method further includes a step of molding the second component through the through hole to form the reinforcement portion or the locking fixing portion.

[0078] (Aspect 14) The method described in Aspect 12 or 13, wherein the first component has at least two opposing upright walls having end edges, and the method further includes the steps of molding the reinforcing portion within the interior of the first component from one end edge to an opposing end edge, and forming the locking fixing portion on the outer surface of the first component from one end edge to an opposing end edge of the first component, thereby connecting the locking fixing portion to the reinforcing portion at the end edge of the first component.

[0079] (Example 15) A method described in any of Examples 12-14, wherein the first component has at least two opposing upright walls having end edges, and the method further includes a step of molding a frame onto the end edges of the first component to partially cover the outer surface of the first component, thereby surrounding and wrapping the end edges of the first component.

[0080] In general, the present invention may alternatively comprise, consist of, or consist essentially of any suitable components disclosed herein. The present invention is organized to be free or substantially free of any components, materials, ingredients, adjuvants, or species used in the prior art components, or that are not otherwise necessary to achieve the function and / or object of the present invention, whether in addition to or in place of the components. The endpoints of all ranges directed to the same component or property are inclusive and independently combinable (e.g., the range "25% by weight or less, or 5% to 20% by weight" is inclusive of the endpoints and includes all intermediate values ​​of the range, such as "5% to 25% by weight"). The disclosure of a particular group joining a narrower or broader range is not a negation of the broader or larger range. "Combination" includes mixtures, admixtures, alloys, reaction products, and the like. Furthermore, the terms "first," "second," and the like are used herein without denoting any order, quantity, or importance, but rather to denote the distinction of elements. The terms "a" and "an" and "the" are used herein to denote no limitation of quantity and should be construed to encompass both the singular and the plural, unless otherwise stated herein or clearly contradicted by context. "Or" means "and / or" unless otherwise specified. The suffix "(s)" as used herein includes both the singular and the plural of the term it modifies. References throughout this specification to "embodiments" indicate that a particular element (e.g., a feature, structure and / or characteristic) described in connection with an embodiment is included in at least one embodiment described herein and may or may not be present in another embodiment. It is further understood that the described elements may be combined in any suitable manner in the various embodiments. "At least one of A, B, or C" is equivalent to "a combination including A, B, C, and at least one of them." That is, there is one or more members of the group.For example, "the geometric shapes of an oval, a square, a rectangle, a triangle, a rhombus, a pentagon, a hexagon, a heptagon, and an octagon, and combinations comprising at least one of the foregoing geometric shapes" is equivalent to "at least one of the geometric shapes of an oval, a square, a rectangle, a triangle, a rhombus, a pentagon, a hexagon, a heptagon, or an octagon."

[0081] "Optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances in which the event occurs and instances in which the event does not occur. Unless otherwise specified, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0082] 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 an incorporated reference, the term from this application takes precedence over the conflicting term from the incorporated reference. This application claims priority to U.S. Provisional Patent Application No. 62 / 483,560, filed April 10, 2017, which is incorporated herein in its entirety.

[0083] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents, which may be unforeseen or presently unforeseen, may occur to the applicant or another person skilled in the art. Accordingly, the appended claims, as filed or as they may be amended, are intended to cover all such alternatives, modifications, variations, improvements, and substantial equivalents. [Explanation of symbols]

[0084] 100,200,300,400 Hybrid structure, 101,201,301 End edge of hybrid structure, 111,211,311,411 Base, 110,210,310,410 First component, 112,212,312,412 Upstanding wall, 113,213,313,413 Through hole, 114,214,314,414 Interior / channel of first component, 115,215,315,415 Outer surface of first component, 116,216,316 Further through hole, 117,217,317 End edge of first component, 218,318,418 Recess, 218a,318a,418a : Branch, 219,319,419 Raised portion, 219a, 319a, 419a Branch, 120, 220, 320, 420 Second component, 121, 221, 321, 421 Reinforcement portion, 122, 222, 322, 422 Hybrid structure channel, 123, 223, 323, 423 Reinforcement portion chamber wall, 124, 224, 324, 424 Lock fixing portion, 125, 225, 325, 425 Ribbon-like lock fixing portion, 126, 226, 326 Frame, 227, 327, 427 Flow tip, 428 Upright wall, 229, 329 Adjacent portion / base of second component, 500 Vehicle body frame, 501 Floor rocker, 502 B-pillar, 503 Roof rail, 504 A-pillar.

Claims

1. A hybrid structure, a first component having a base and an upstanding wall extending from the base, the first component having an interior enclosed between the upstanding wall and the base; a thermoplastic second component molded to said first component, said second component comprising a reinforcing portion for structurally reinforcing said first component, said reinforcing portion extending longitudinally of said first component and being internal to said first component, said thermoplastic second component further comprising a locking portion extending adjacently over at least a portion of an outer surface of said first component, said reinforcing portion and said locking portion being integrally formed thereby interlocking said first component within said thermoplastic second component; on an outer surface of the first component, the base portion is provided with a first undulation extending in a longitudinal direction of the first component, the locking portion adjacent the outer surface of the first component extending in the longitudinal direction together with the first undulation; and / or Within the first component, the base has a second undulation, and the second component extends in the longitudinal direction with the second undulation; The first component includes a through hole, and the locking portion passes through the through hole and connects to the reinforcement portion. Hybrid structure.

2. A hybrid structure, a first component having a base and an upstanding wall extending from the base, the first component having an interior enclosed between the upstanding wall and the base; a thermoplastic second component molded to said first component, said second component comprising a reinforcing portion for structurally reinforcing said first component, said reinforcing portion extending longitudinally of said first component and being internal to said first component, said thermoplastic second component further comprising a locking portion extending adjacently over at least a portion of an outer surface of said first component, said reinforcing portion and said locking portion being integrally formed thereby interlocking said first component within said thermoplastic second component; and / or the base is provided with a first undulation on an outer surface of the first component extending in a longitudinal direction of the first component, the locking portion adjacent the outer surface of the first component extending in the longitudinal direction together with the first undulation; Within the first component, the base has a second undulation, and the second component extends in the longitudinal direction with the second undulation; the first component has at least two opposing upstanding walls having end edges, the reinforcing portion extends from one end edge to an opposing end edge of the first component, and the locking portion extends on an outer surface of the first component from the one end edge to the opposing end edge of the first component, thereby connecting with the reinforcing portion at the end edge of the first component; Hybrid structure.

3. A hybrid structure, a first component having a base and an upstanding wall extending from the base, the first component having an interior enclosed between the upstanding wall and the base; a thermoplastic second component molded to said first component, said second component comprising a reinforcing portion for structurally reinforcing said first component, said reinforcing portion extending longitudinally of said first component and being internal to said first component, said thermoplastic second component further comprising a locking portion extending adjacently over at least a portion of an outer surface of said first component, said reinforcing portion and said locking portion being integrally formed thereby interlocking said first component within said thermoplastic second component; and / or the base is provided with a first undulation on an outer surface of the first component extending in a longitudinal direction of the first component, the locking portion adjacent the outer surface of the first component extending in the longitudinal direction together with the first undulation; Within the first component, the base has a second undulation, and the second component extends in the longitudinal direction with the second undulation; the reinforcing portion comprises a honeycomb structure with channels oriented transversely to a base of the first component; Hybrid structure.

4. A hybrid structure, a first component having a base and an upstanding wall extending from the base, the first component having an interior enclosed between the upstanding wall and the base; a thermoplastic second component molded to said first component, said second component comprising a reinforcing portion for structurally reinforcing said first component, said reinforcing portion extending longitudinally of said first component and being internal to said first component, said thermoplastic second component further comprising a locking portion extending adjacently over at least a portion of an outer surface of said first component, said reinforcing portion and said locking portion being integrally formed thereby interlocking said first component within said thermoplastic second component; on an outer surface of the first component, the base portion is provided with a first undulation extending in a longitudinal direction of the first component, the locking portion adjacent the outer surface of the first component extending in the longitudinal direction together with the first undulation; and / or Within the first component, the base has a second undulation, and the second component extends in the longitudinal direction with the second undulation; The first component is a composite component, a metallic component, or a composite / metallic hybrid component. Hybrid structure.

5. 5. The hybrid structure of claim 4, wherein the hybrid structure is a reinforcement member for a body frame of a vehicle, the reinforcement member being connectable to the body frame by at least one of mechanical fasteners, welding, and adhesives.

6. A vehicle comprising the hybrid structure according to any one of claims 1 to 5.

7. A vehicle having a hybrid structure, The hybrid structure comprises: a first component having a base and an upstanding wall extending from the base, the first component having an interior enclosed between the upstanding wall and the base; a thermoplastic second component molded to said first component, said second component comprising a reinforcing portion for structurally reinforcing said first component, said reinforcing portion extending longitudinally of said first component and being internal to said first component, said thermoplastic second component further comprising a locking portion extending adjacently over at least a portion of an outer surface of said first component, said reinforcing portion and said locking portion being integrally formed thereby interlocking said first component within said thermoplastic second component; on an outer surface of the first component, the base portion is provided with a first undulation extending in a longitudinal direction of the first component, the locking portion adjacent the outer surface of the first component extending in the longitudinal direction together with the first undulation; and / or Within the first component, the base has a second undulation, and the second component extends in the longitudinal direction with the second undulation; a structural body frame, the hybrid structure forming a portion of the structural body frame and forming 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. vehicle.

8. A method for producing a hybrid structure, comprising: The hybrid structure comprises: a first component having a base and an upstanding wall extending from the base, the first component having an interior enclosed between the upstanding wall and the base; a thermoplastic second component molded to said first component, said second component comprising a reinforcing portion for structurally reinforcing said first component, said reinforcing portion extending longitudinally of said first component and being internal to said first component, said thermoplastic second component further comprising a locking portion extending adjacently over at least a portion of an outer surface of said first component, said reinforcing portion and said locking portion being integrally formed thereby interlocking said first component within said thermoplastic second component; on an outer surface of the first component, the base portion is provided with a first undulation extending in a longitudinal direction of the first component, the locking portion adjacent the outer surface of the first component extending in the longitudinal direction together with the first undulation; and / or Within the first component, the base has a second undulation, and the second component extends in the longitudinal direction with the second undulation; The method comprises: providing the first component; providing the first component with the thermoplastic second component by molding the reinforcing portion within the first component and molding the locking portion on an exterior surface of the first component to cover at least a portion of the exterior surface, wherein the reinforcing portion and the locking portion are integrally molded, thereby interlocking the second component with the first component.

9. 9. The method of claim 8, wherein the base and / or the upstanding wall of the first component have a through hole, the method further comprising molding the second component through the through hole to form the reinforcement portion or the locking portion.

10. 9. The method of claim 8, wherein the first component has at least two opposing upstanding walls having end edges, the method further comprising the steps of: molding the reinforcing portion within the interior of the first component from one end edge to an opposing end edge; and molding the locking portion on an exterior surface of the first component from the one end edge to the opposing end edge of the first component, thereby connecting the locking portion with the reinforcing portion at the end edge of the first component.

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