Lightweight component for bearing elements of motor vehicles

Abstract

A lightweight, plastic coated component is in the shape of a three-dimensional shaped part with a metal layer provided with access apertures through which the plastic may flow. The component includes stiffening ribs created by the plastic that are positioned within hollow areas of the three-dimensional shaped part, and whose plastic extends through the apertures of the metal insert. The component is formed as a metal insert spray-covered with plastic for the purposes of optimizing the plastic spray process and to achieve an inner bond between the metal insert and the stiffening ribs. The metal insert includes a large number of evenly-distributed holes, and these holes form a flow resistance and also a flow enabler for the molten mass of plastic during spraying. There are projections present at each of the holes that are covered by the plastic coating. The stiffening ribs facing away from the sprayed side have a connecting cross-section that extends into the metal insert via a number, or a large number, of holes in the metal insert.

1 . A lightweight component that is resistant to flex and torsion in the shape of a flat, three-dimensionally deformed shape with a metal insert possessing penetrating holes along with projections next to them, that includes the flat, three-dimensionally deformed shape, and with stiffening ribs that are positioned at least on one side on the flat shape within hollow areas formed by the three-dimensional shape, whereby the metal insert is spray-coated from an injection side with a plastic that forms a plastic coating on the injection side and that forms the stiffening ribs by flowing through the penetrating holes of the metal insert, 
 characterized in that    the penetrating holes of the metal insert are positioned in large numbers with regular distribution in the the projections at each of the penetrating holes of the metal insert correspond at least to the thickness of the plastic coating,    and that the stiffening ribs possess a fitting cross-section that extends over many, or a large number, of the penetrating holes in the metal insert.    
   
   
       2 . A lightweight component as in  claim 1 , 
 characterized in that    the injection side is the visible side when in the mounted position on which the thickness of the plastic coating is greater than the height of the projections at the holes, and correspondingly the visible side in the coated area is completely formed by the plastic.    
   
   
       3 . A lightweight component as in  claim 2 , 
 characterized in that    the surface of the plastic flowing through the holes of the metal insert lies on the inner side facing away from the injection side to bond with it, or extends over it.    
   
   
       4 . A lightweight component as in  claim 1 , 
 characterized in that    the projections are recesses hollowed out from the basic surface of the metal insert that possess half-sided apertures that form the apertures of the holes in the metal insert.    
   
   
       5 . A lightweight component as in  claim 4 , 
 characterized in that    the projections are approximately the shape of a hollow quarter sphere.    
   
   
       6 . A lightweight component as in  claim 4 , 
 characterized in that    the apertures of the holes created from the metal insert corresponding to the projections on the injection side each lies in a plane that is perpendicular, or almost perpendicular, to the base surface of the metal insert.    
   
   
       7 . A lightweight component as in  claim 4 , 
 characterized in that    the apertures of the holes at the projections hollowed out from the metal insert lie in planes that are parallel with one another.    
   
   
       8 . A lightweight component as in  claim 4 , 
 characterized in that    the apertures of the holes at the projections hollowed out from the metal insert are divided into two or more groups whereby the apertures of the holes of one group lie in planes that are parallel with one another, and the planes of the holes of the group are at an angle to one another.    
   
   
       9 . A lightweight component as in  claim 7 , 
 characterized in that    the apertures of the holes at the hollowed-out projections of the metal insert lying in parallel planes to the base surface of the metal insert point in the same direction perpendicular to the plane of each hole and parallel, or almost parallel, base surface of the metal insert.    
   
   
       10 . A lightweight component as in  claim 1 , 
 characterized in that    the projections at the holes are partially positioned on the inner side of the metal insert.    
   
   
       11 . A lightweight component as in  claim 1 , 
 characterized in that    the metal insert includes coated as well as uncoated areas and the sieve structure with holes and the projections are present only in the coated areas.    
   
   
       12 . A lightweight component as in  claim 1 , 
 characterized in that    the metal insert possesses an enclosed wall section in the vicinity of at least one injection point on the injection side, or of a mouth point of a flow channel for the plastic that correspondingly transforms into a wall section provided with the holes at which the stiffening ribs attach to the inner side of the metal insert.    
   
   
       13 . A plastic coated, metal core, lightweight component comprising: 
 a metal insert having a plastic coating application side, said metal insert including a plurality of holes penetrating through said plastic coating application side of said metal insert and disposed about at least a portion of said metal insert, and a corresponding plurality of projections on a side opposite from said plastic coating application side, said projections located proximate said holes and having approximately the shape of a hollow quarter sphere; and    a plastic coating applied to said plastic coating application side of said metal insert and covering at least a portion of said metal insert, and whereby the plastic coating flowing through at least some of said penetrating holes in the metal insert forms stiffening ribs.