Composite part and method for the production thereof

Abstract

Process for producing a composite structural element from a metal structural element ( 4 ) and a plastics structure ( 1 ), in which the metal structural element, which has at least one surface with at least one punched rim or punched collar ( 7 ), and the plastics structure are pressed together with the aid of one or more joining tools ( 11, 13, 26, 29, 32, 37 ), the punched rim/collar penetrating into or through the plastics structure in a positively and nonpositively locking manner.

We claim:  
     
         1 . A process for producing a composite structural element from a metal structural element ( 4 ) and a plastics structure ( 1 ), wherein the metal structural element, which has at least one surface with at least one punched rim or punched collar ( 7 ), and the plastics structure are pressed together with the aid of one or more joining tools ( 11 ,  13 ,  26 ,  29 ,  32 ,  37 ), the punched rim/collar penetrating into or through the plastics structure in a positively and nonpositively locking manner.  
     
     
         2 . A process for producing a composite structural element from a metal structural element ( 4 ) and a plastics structure ( 1 ), wherein the plastics structure is injection-molded in an injection mold ( 31 ), the injection mold is opened, a metal structural element ( 4 ) which has at least one surface with at least one punched rim ( 7 ) is introduced into the opened injection mold and positioned over or in front of the plastics structure remaining in the injection mold, and the injection mold halves ( 32 ,  37 ) are moved together, the punched rim or rims being pressed into the plastics structure in a positively and nonpositively locking manner.  
     
     
         3 . A process as claimed in  claim 2 , wherein a female die ( 33 ), which corresponds on the front side, at least in the region of the joining locations, substantially to the contour of the surface of the metal structural element, is introduced into the injection mold between the metal structural element ( 4 ) and the rear injection mold half ( 37 ) and is positioned.  
     
     
         4 . A process as claimed in  claim 3 , wherein the rear side of the female die comes to bear against the rear injection mold half ( 38 ), or against the platen of this mold half, when the mold halves ( 32 ,  37 ) are pressed together.  
     
     
         5 . A process as claimed in  claim 3  or  4 , wherein the female die ( 33 ) and metal structural element ( 4 ) are placed one on top of the other outside the injection mold and are introduced as a unit into the opened injection mold and positioned over or in front of the plastics structure.  
     
     
         6 . A process as claimed in  claims 1  to  5 , wherein the punched rim is attached substantially perpendicularly on the metal surface.  
     
     
         7 . A process as claimed in  claims 1  to  6 , wherein the end of the punched rim is edged, in particular sharply edged.  
     
     
         8 . A process as claimed in  claims 1  to  7 , wherein the height of the punched rim exceeds the thickness of the plastics structure at the location to be connected by up to 40%.  
     
     
         9 . A process as claimed in  claims 1  to  7 , wherein the height ( 7 . 1 ) of the elevation or of the punched rim ( 7 ) lies below the wall thickness ( 1 . 1 ) of the plastics structure ( 1 ) or is equal to the wall thickness ( 1 . 1 ) of the plastics structure.  
     
     
         10 . A process as claimed in one of  claims 1  to  9 , wherein the punched rim represents a punched collar of an aperture through the metal surface of the metal structural element.  
     
     
         11 . A process as claimed in  claims 1  to  10 , wherein the elevation or the punched rim ( 7 ) has a constriction, indentation or depression ( 25 ) on at least one punched collar side face.  
     
     
         12 . A process as claimed in  claims 1  to  11 , wherein the surface ( 27 ) of the metal plate is deflected in the region around the punched rim/collar with respect to the surface defined by the surrounding metal plate ( 28 ) in the direction of the punched collar base, so that the height of the punched rim/collar determined with respect to the surface defined by the surrounding metal plate is less than the actual height determined by the punched rim/punched collar base.  
     
     
         13 . A process as claimed in  claims 1  to  12 , wherein the surfaces to be connected of the metal structural element and the plastics structure are partially or completely provided with an adhesive before the joining operation.  
     
     
         14 . A process as claimed in  claims 1  to  13 , wherein the joined locations are provided with an adhesive or a sealing compound in the region of the punched collar base and, if appropriate, in the region of the punched collar aperture.  
     
     
         15 . A process as claimed in  claims 1  to  14 , wherein the plastics structure is in a warmed state during the joining operation or the composite structural element is heat-treated after the joining operation.  
     
     
         16 . Composite structural elements which can be obtained by a process as claimed in  claims 1  to  15 .  
     
     
         17 . The use of composite structural elements as claimed in  claim 16  as structural elements or structural element components in automotive engineering or aircraft construction or shipbuilding or in the production of domestic or electrical appliances.  
     
     
         18 . The use as claimed in  claim 17 , the structural element or the structural element components for automotive engineering taking the form of front-end modules, front-end supports, seat pans, seat structures, instrument panels, functional supports for doors, functional modules for doors, tailgates or side doors.  
     
     
         19 . Front-end modules, front-end supports, seat pans, seat structures, side doors, instrument panel supports, functional supports for doors, functional modules for doors, tailgates, washing machines, refrigerators or dishwashers containing a composite structural element as claimed in  claim 16.