# US 12,110,063 B2 · Hybrid component and method for manufacturing a hybrid component > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,110,063 B2 - Document ID: US12110063B2 - Status: Granted - Kind: B2 - Application number: 17/267,167 - Filed: 2019-07-11 - Published: 2021-10-07 - Granted: 2024-10-08 - Earliest claimed: 2018-08-10 - Assignees: Bayerische Motoren Werke Aktiengesellschaft - Applicants: Bayerische Motoren Werke Aktiengesellschaft - Inventors: Patrick Mueller; Dominik Paulke; Christof Schoenhammer; Jean-Marc Segaud - Web page: https://patentgrep.com/patent/US12110063B2 ## CPC - B62D 27/02: rigid - B29C 45/0055: {Shaping} - B29C 45/14819: {the inserts being completely encapsulated} - B62D 29/00: Superstructures, {understructures, or sub-units thereof,} characterised by the material thereof {(B62D33/044, B62D33/048 take precedence)} - B62D 29/004: {the metal being over-moulded by the synthetic material, e.g. in a mould} - B29C 2045/0058: {removing material} - B29K 2705/02: Aluminium - B29K 2705/12: Iron - B29L 2031/30: Vehicles, e.g. ships or aircraft, or body parts thereof {(vanes or blades B29L2031/08, air bags B29L2022/027)} - B62D 29/001: {characterised by combining metal and synthetic material} - B62D 29/008: {predominantly of light alloys, e.g. extruded} - B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract A hybrid component has at least two component portions, which are connected via at least one connection portion. The at least one connection portion extends in a joining direction. A first component portion is formed from a first material which has a first modulus of elasticity, and a second component portion is formed from a second material which has a second modulus of elasticity different from the first modulus of elasticity. The at least one connection portion is designed at least to compensate for a sudden change in rigidity between the two component portions. The at least one connection portion has a rigidity that increases in the joining direction and in the direction of the component portion with the higher modulus of elasticity. ## Claims ### Claim 1 A hybrid component, comprising: at least first and second component portions, the first component portion being formed from a first material which has a first modulus of elasticity, and the second component portion being formed from a second material which has a second modulus of elasticity different than the first modulus of elasticity; at least one connecting portion by which the first and second portions are connected, the at least one connecting portion extending in a joining direction, wherein the at least one connecting portion is formed either as an insert element, or from one of the first and second component portions; wherein the at least one connecting portion is configured to compensate for a jump in stiffness between the first and second component portions, the at least one connecting portion having a variable perforation or hole pattern extending in the joining direction to create a stiffness which gradually increases in the joining direction, toward the component portion with the higher modulus of elasticity; and, wherein a modulus of elasticity in the connecting portion gradually increases in the joining direction, toward the component portion with the higher modulus of elasticity, the increase in the modulus of elasticity, or the slope, being between 0.5 to 1.5. ### Claim 2 (depends on 1) The hybrid component according to claim 1, wherein the modulus of elasticity increases linearly in the joining direction, toward the component portion with the higher modulus of elasticity. ### Claim 3 (depends on 1) The hybrid component according to claim 1, wherein the variable perforation or hole pattern has holes and/or recesses which have a different size, density, distribution and/or orientation extending in the joining direction. ### Claim 4 (depends on 1) The hybrid component according to claim 1, wherein the insert element comprises two connecting portions. ### Claim 5 (depends on 4) The hybrid component according to claim 4, wherein a free portion is provided between the two connecting portions of the insert element. ### Claim 6 (depends on 5) The hybrid component according to claim 5, wherein the free portion has a pattern of holes and/or recesses extending in the joining direction. ### Claim 7 (depends on 1) The hybrid component according to claim 1, wherein a material of the insert element has a modulus of elasticity which is between the modulus of elasticity of the first material and the modulus of elasticity of the second material. ### Claim 8 (depends on 1) The hybrid component according to claim 1, wherein the first material is a metal and the second material is a nonmetal. ### Claim 9 A method for manufacturing a hybrid component, comprising the steps of: providing an element of a first material; encapsulating the element, at least in certain regions, in a second material along a connecting portion, wherein the connecting portion extends along a joining direction and is formed from one of the first and second materials, wherein the first material has a modulus of elasticity different than the second material; shaping the connecting portion with a variable perforation or hole pattern extending in the joining direction such that its stiffness gradually increases in the joining direction, toward the material with the higher modulus of elasticity; and, wherein a modulus of elasticity in the connecting portion gradually increases in the joining direction, toward the component portion with the higher modulus of elasticity, the increase in the modulus of elasticity, or the slope, being between 0.5 to 1.5. ### Claim 10 (depends on 9) The method according to claim 9, further comprising the step of: shaping the connecting portion by machining. ### Claim 11 (depends on 9) The method according to claim 9, wherein the second material is a plastic, and further comprising the step of: encapsulating the element in the second material in an injection-molding operation. ### Claim 12 (depends on 9) The method according to claim 9, wherein the connecting portion is shaped with the variable perforation or hole pattern in the joining direction such that the modulus of elasticity generally increases linearly in the joining direction, toward the material with the higher modulus of elasticity. ### Claim 13 (depends on 12) The method according to claim 12, wherein the connecting portion is shaped with the variable perforation or hole pattern such that holes and/or recesses have a different size, density, distribution and/or orientation extending in the joining direction. ### Claim 14 (depends on 1) The hybrid component according to claim 1, wherein the variable perforation or hole pattern has holes and/or recesses which have a different size, density, distribution and/or orientation extending in the joining direction. ### Claim 15 (depends on 1) The hybrid component according to claim 1, wherein the variable perforation or hole pattern comprises at least three perforations or holes extending in the joining direction. ### Claim 16 (depends on 9) The method according to claim 9, wherein the variable perforation or hole pattern comprises at least three perforations or holes extending in the joining direction.