HYBRID COMPONENT FOR AUTOMOTIVE APPLICATIONS AND METHOD OF MANUFACTURING A HYBRID COMPONENT

Abstract

A hybrid component is provided for automotive applications, and includes a sheet metal component and at least one plastic support component. The at least one plastic support component is positively connected to the sheet metal component. A decor section of the sheet metal component includes a colour coating pattern generating a dedicated aesthetic design appeal.

Claims

1. A hybrid component for automotive applications, the hybrid component comprising: a sheet metal component; and at least one plastic support component positively connected to the sheet metal component; wherein a decor section of the sheet metal component includes a colour coating pattern generating a dedicated aesthetic design appeal.

2. The hybrid component according to claim 1, wherein the decor section includes an anodised layer, wherein the colour coating pattern is enclosed in the anodised layer.

3. The hybrid component according to claim 1, wherein the decor section is covered by a transparent or translucent protection layer.

4. The hybrid component according to claim 1, wherein the sheet metal component further includes at least one opening, wherein the opening is a sensor window or allows for backlighting.

5. The hybrid component according to claim 4, wherein a cover pane and/or a metal mesh is inserted in the opening, and is connected to the sheet metal component and/or to the plastic support component.

6. The hybrid component according to claim 1, wherein the sheet metal component includes an aluminium alloy.

7. The hybrid component according to claim 1, wherein the plastic support component includes a stiffening structure and/or mounting means.

8. A method of manufacturing a hybrid component for automotive applications, the method comprising the following steps without a fixed order: providing a sheet metal component made of an aluminium alloy, applying a colour coating pattern to a decor section of the sheet metal component generating a dedicated aesthetic design appeal, and injection-moulding at least one plastic support component to the sheet metal component forming a positive connection.

9. The method according to claim 8, wherein the colour coating pattern is applied by inkjet printing, pad printing, screen printing, lacquering or by attaching a foil or a sticker.

10. The method according to claim 8, wherein the decor section is anodized before applying the colour coating pattern, wherein the decor section is sealed after applying the colour coating pattern.

11. The method according to claim 8, wherein a transparent or translucent protection layer is injection-moulded to the decor section after applying the colour coating pattern.

12. The method according to claim 8, wherein the sheet metal component is provided with at least one opening, and with a cover pane and/or a metal mesh inserted in the opening, wherein the injection-moulding creates a positive connection of the plastic support component and the cover pane and/or the metal mesh.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Reference is now made more particularly to the drawings, which illustrate the best presently known mode of carrying out the invention and wherein similar reference characters indicate the same parts throughout the views.

[0022] FIGS. 1-3 illustrate front views of intermediate products of the method of manufacturing a hybrid component.

[0023] FIG. 4a is a front view of a first embodiment of the hybrid component.

[0024] FIG. 4b is a rear view of the first embodiment.

[0025] FIG. 4c is a cross-section view of the first embodiment.

[0026] FIG. 5a is a front view of a second embodiment of the hybrid component.

[0027] FIG. 5b is a rear view of the second embodiment.

[0028] FIG. 5c is a cross-section view of the second embodiment.

DETAILED DESCRIPTION OF THE DRAWINGS

[0029] FIG. 1 to FIG. 3 show front views of intermediate products of the method of manufacturing a hybrid component according to the invention.

[0030] FIG. 1 shows the sheet metal component 1, the entire front side of which forms the decor section 11. In an intended installation position as a panel in the front of a motor vehicle, the decor section 11 is visible to a passer-by. The sheet metal component 1 is preferably made of an aluminium alloy and has a thickness of, for example, 1-2 mm. The sheet-metal component 1 can be shaped by a conventional forming process, for example a punching-bending process. The sheet metal component 1 has the opening 5 which is provided as a sensor opening for a radar sensor to be arranged behind it.

[0031] FIG. 2 shows the sheet metal component 1, wherein a cover pane 6 transparent to radio waves, for example made of polycarbonate, has been inserted into the opening 5. For further handling, the cover pane 6 can be attached to the sheet metal component 1 by means of a temporary pre-fixation.

[0032] FIG. 3 shows the sheet metal component 1 after the application of the colour coating pattern 3 to the decor section 11. The colour coating pattern 3 consists here, as an example, of a coloured, semi-transparent covering of the entire decor section 11 (not visible in the black and white line graph of FIG. 3), through which the metallic surface appearance of the decor section 11 remains visible, as well as of the additionally applied lettering TURBO in a different colour. The cover pane 6 is also covered by the colour coating pattern 3.

[0033] FIG. 4a to FIG. 4c show a front, rear and cross-section view of a first embodiment of the hybrid component 100 according to the invention, in which the plastic support components 2 have been positively connected to the sheet metal component 1 by means of injection-moulding as the final step of the manufacturing process in this example. The rib-shaped stiffening structures 21 and the mounting means 22 in the form of screw bosses form sections of the plastic support components 2. The stiffening structures 21 counteract deflection of the sheet metal component 1 and the mounting means 22 serve to connect the hybrid component 100 to a motor vehicle or to arrange a radar unit behind the opening 5 with the cover pane 6. The cover pane 6 is positively connected to the corresponding plastic support component 2 and integrated into the hybrid component 100 via the latter.

[0034] FIG. 5a to FIG. 5c show a front, rear and cross-section view of a second embodiment of the hybrid component 100 according to the invention, in which the decorative section 11 of the sheet metal component 1 together with the colour coating pattern 3 applied thereto is covered by the transparent protection layer 4. The protection layer 4 consists of a suitable plastic and has been attached to the sheet metal component 1 by means of injection-moulding. Due to the transparency of the protective layer 4, the metallic-looking surface of the decorative section 11 and the colour coating pattern 3 are still visible. The protection layer 4 serves as a wear protection layer, in particular against scratching and/or UV bleaching.

[0035] The present invention is not limited by the embodiments described above which are represented as examples only and can be modified in various ways within the scope of protection defined by the appending patent claims.

LIST OF NUMERALS

[0036] 100 hybrid component [0037] 1 sheet metal component [0038] 11 decor section [0039] 2 plastic support component [0040] 21 stiffening structure [0041] 22 mounting means [0042] 3 colour coating pattern [0043] 4 protection layer [0044] 5 opening [0045] 6 cover pane