Shaped Two-Dimensional Semifinished Part, Structured or Hybrid Component and Method for Producing Such a Semifinished Part or Component

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This patent describes a method and product for creating hybrid components or semi-finished parts that combine metal or fiber-reinforced plastic inserts with injection-molded plastic. The innovation lies in using the melt pressure from the injection molding process to permanently deform the insert material (such as sheet metal or fiber-reinforced plastic) in specific regions. This process enables strong, form-fitting mechanical bonds between the insert and the plastic without requiring complex pre-processing of the insert (like drilling or notching). The resulting parts are lightweight yet mechanically robust, making them well-suited for structural applications where weight savings are critical.

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• Automotive body structures and internal components for lighter, stronger vehicles
• Aerospace components needing high strength-to-weight ratios
• Railway car parts for weight reduction and improved safety
• Industrial equipment or machinery with hybrid, load-bearing parts
• Consumer electronics housings requiring rigidity and impact resistance
• Sporting goods, such as bicycles or helmets, with enhanced structural properties

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• Enables lightweight construction through intelligent material combination, reducing overall product weight
• Yields components with high mechanical strength and rigidity despite lower weight
• Simplifies manufacturing by integrating insert deformation and bonding in a single injection molding step
• Improves cost efficiency by reducing pre-processing and assembly steps
• Allows flexible customization of mechanical properties by adjusting materials or design
• Supports the use of recyclable or energy-efficient materials (such as aluminum or magnesium)
• Achieves stronger bonds and increased durability compared with traditional fastening techniques (e.g., rivets or adhesives)

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Patent Abstract

The molded, flat semi-finished product, comprising at least one reinforcing inlay of metal or plastic which is at least partially embedded in an injection molded plastic, has the reinforcing inlay provided with a section which is permanently deformed by the melting pressure of the plastic which is worked in the injection molding process. The reinforcing inlay may be formed by metal sheet or from a fiber-reinforced plastic. The section of the inlay which is deformed by the melting pressure of the injection molded plastic is plastically deformed. Independent claims are included for the following: (1) a composite structure or hybrid component consisting of at least two different materials; and (2) a method for producing a flat semi-finished product or composite structure.