DE102017002916A1 - Three-dimensional elements - Google Patents

Abstract

The invention relates to integral three-dimensional elements for moving objects having spatial extensions in at least two spatial directions and a non-zero extension in a third spatial direction, wherein additional functions and, or properties are implemented in an integrative manner.

Description

The invention relates to integral three-dimensional elements for moving objects having spatial extensions in at least two spatial directions and a non-zero extension in a third spatial direction.

Three-dimensional elements in the form of machine elements, installation elements, pieces of furniture, panels, volume-forming containers, body-like enclosures or housings, etc. are in a variety of one- or multi-part designs consisting of one or more materials such as wood, metals, non-ferrous metals, plastics, composite materials, laminates long known and used in virtually all areas of technology elements.

Under three-dimensional elements, all elements are generally understood to have a spatial extent in at least two spatial directions and a non-zero extension in a third spatial direction.

Three-dimensional elements and in particular built-in parts in or for moving objects such as air, water or land vehicles are often realized in several parts. This means that the extension of such built-in parts is carried out in three spatial directions by a plurality of interconnected detachably or non-detachably connected sub-elements. The cause is a previously missing manufacturing process from the viewpoint of economy, ecology, freedom of design.

The established manufacturing processes and forming processes such as primary forming, forming, chip-forming and non-cutting processing methods and or for the connection of subcomponents of three-dimensional elements available joining methods such as fabric bond, positive engagement, adhesion through, for example, screwing and or gluing and or rivets and, or Welding offers only limited possibilities for the realization of such components and is often too inflexible and costly.

Another known manufacturing method for creating complex geometries of particular plastic materials or non-ferrous metals such as aluminum and magnesium is injection molding. In this method, a previously molten or at least teilplastifizierter material is introduced into a mold. This process, which is frequently performed under high pressure, requires a mold designed as a mostly two-part or multi-part tool, the cavity of which can be opened by two or more parts in order to be able to remove the injection-molded workpiece after it has hardened.

The injection molding process is limited due to the mandatory demouldability of the workpiece from the tool in its geometry design freedom. The tools with increasing geometry complexity by the then required multi-part complexity and very expensive. As a result, injection molding processes are only suitable for limited geometry complexities and significant quantities.

In built-in parts in moving objects often additional criteria to the aforementioned conditions additively or alternatively added.

In addition to economic and aesthetic aspects, as well as the undesirable limitations in terms of geometry complexity, the catalog of requirements for lightweight components, temperature stability, deformation stiffness or targeted deformation ability both partial-local and the whole component, material combinations, surface textures to support increased or reduced adhesion or sliding friction properties, taste surface appearances, considerable Wanddickengradienten in the spatial extent at least in one spatial direction, etc. must be added.

Another difficulty of three-dimensional elements in the form of built-in parts for moving objects can arise from the fact that different of the aforementioned criteria, requirements or boundary conditions are contrary to each other. Particularly noteworthy are the functional criteria or component properties and the capital employed for the production facilities, whose profitability is in turn dependent on the number of units.

In the production of fixtures for moving objects in larger numbers, such as cars, commercial vehicles or water, air and rail vehicles, these are often produced for example as plastic, aluminum or magnesium parts by injection molding or injection molding or by Ur- and forming process ,

In the manufacture of low volume fixtures for moving objects where the capital intensive injection molding or forming tools are not economically viable for fixture fabrication, flexible fabrication methods are needed.

Elements with a smaller number of units are produced, for example, in a manner of craftsmanship. As materials are often used wood and, or wood composite parts - partly with inner core of honeycomb or other geometrically suitable stiffeners. Also aluminum, metal materials or plastics as base material or semi-finished are used. Elements of this type are usually constructed in several parts and are processed by known machining processes such as sawing, drilling, milling, bending, forming and connected with suitable connection and joining techniques such as screws, pins, rivets, gluing, welding to form a three-dimensional element.

In addition to the established manufacturing processes and forming processes, so-called 3D printing has recently been developed.

3D printing production methods today include a variety of different techniques for making three-dimensional elements. All 3D printing processes have in common that they build up elements with extension in three spatial directions in layers. Unlike the known original and forming methods and subtractive methods, which include the chip-forming and non-cutting material-removing processes, the group of 3D printing production methods is characterized by the additive material insertion or additive, layered workpiece structure.

In order to realize the additive and layered workpiece structure, for example, nozzles are used as printheads which apply a previously plasticized or at least partially liquefied material in the form of drops, mists or filaments and build up in layers the three-dimensional element to be produced. Another 3D printing method is based on pulverulent or liquid base material whose local layer-wise workpiece formation takes place by partial hardening of the base material.

The hardening process can be initiated and / or completed depending on the base materials used in each case by changing the state of aggregation as a result of cooling, UV curing or even pressing, sintering, chemical reaction, etc.

3D printing processes are available for a variety of materials such as thermoplastics such as ABS or PLA, various resins and resins, plastics such as polyamide, metals such as steel and titanium, non-ferrous metals such as aluminum and magnesium. Preferably, but not necessarily, suitable materials for processing in 3D printers have aggregate change properties.

The object of the invention is to at least partially reduce the aforementioned disadvantages in connection with three-dimensional elements.

The teaching of the invention proposes as a solution integral three-dimensional elements, designed in particular as built-in parts for moving objects and recognizes that their production is particularly advantageous by an additive manufacturing method using 3D printers. A manufacturing polyoptimization of various previously mentioned criteria and, or requirements or boundary conditions in a contrary relationship to each other are possible.

The invention provides that integral three-dimensional elements for moving objects are constructed in layers by additive manufacturing processes. Preferably, but not necessarily, elements according to the invention can be made in one piece. The integration of additional functions and, or properties special elements of the invention are created.

The teaching of the invention supports integral three-dimensional elements designed in particular as built-in parts for moving objects with considerable geometry complexity, for example in the form of cavities, cores and, or inserts, undercuts, extension gradients in at least one spatial direction, virtually any free-form surfaces and wall thickness jumps.

Depending on the purpose of the three-dimensional element for moving objects, additional functions integrated additively or alternatively may comprise a multiplicity of variants. For example, integral three-dimensional elements for moving objects may be implemented as fixtures such as furniture or cabinets in recreational vehicles, boats, airplanes or caravans, and may integrally include conduits, gaskets, divider mounts, hinges, drains, various fluid conduits, solids and, or Gases, cables, fasteners, walls, partitions, brackets, etc. have.

Other variants of the integrated additional functions according to the invention may include at least one sensor or sensor suitable for, for example, the detection of water, gas, acting positive or negative acceleration in accident situations or impacts, movements, approximation of persons or objects, brightness or generally the light exposure situation, etc. ,

The integrated properties also include, depending on the purpose of the Three-dimensional element for moving objects additively or alternatively a variety of variants. For example, integral three-dimensional elements for moving objects can be designed geometrically such that specific strength, rigidity and / or deformation properties are impressed. Integral properties of this type are based primarily on geometric designs produced by additive manufacturing processes with layered structure according to the invention. Geometric configurations can be element-side cores, for example, in the form of notch stress-reducing radii, stiffening honeycomb structures and / or strength-increasing folds.

Further inventive integration options in three-dimensional elements are supported by introduced material combinations. These combinations, realized as separate components or modules with smooth transition, may include various plastics, aluminum, steel, paper, and so on. The same applies to color designs, surface structures and generally for property-based optical influences.

The invention makes it possible in a special way, the generally desired mass reduction of three-dimensional elements by the integrated properties. Depending on the requirement catalog of the element, depending on the properties, an optimum basic or workpiece material for the layered additive structure can be selected. The same applies to the targeted wall thickness training of the entire element or partial areas. For example, a furniture carcass may be made in at least one piece from a light plastic sandwich with an inner honeycomb structure, integrated stiffening frame made from the same and / or compatible second material, or aluminum, steel, magnesium, etc. in layers. As a result of the integrative design of such three-dimensional elements according to the invention, there is a great potential for mass minimization, which is of particular relevance especially for built-in parts for moving objects.

As an additive or as an alternative to the mass reduction advantages, the material combination degree of freedom supported by the invention can offer special integration possibilities which conventional production methods can not realize and which supports additional integrative functions and properties.

A significant further advantage of the teaching according to the invention consists in rapid and uncomplicated changes in the geometry, dimensions in absolute or relative terms as well as proportion modification of the integral three-dimensional elements. As a result of the additive manufacturing process in the context of layer-by-layer element construction, only the process-controlling parameters and, if appropriate, the base material or materials used are to be changed. Also supported are complicated shapes, geometries in individual areas or the entire integral three-dimensional element.

The layered element structure by the additive 3D printing process further supports the optical properties of the three-dimensional elements in terms of, for example, the coloring and, or surface texture in many ways. The respective surface layers can be formed by material variants, colors, surface structures and / or embossing, roughness depths as well as by changes in the refractive, light-emitting and light-scattering properties.

According to the invention, surfaces can be embodied as nanostructures and have, for example, properties with regard to self-cleaning, lotus effect, hologram effects or direction-dependent alternating images.

Cost advantages achieved by the invention not only by the reduced monetary cost of the manufacturing and manufacturing means, but also by a significantly reduced personnel costs and high despite a high level of flexibility and small series suitability high degree of automation.

The meaning of the teaching according to the invention is not exhausted in the integration of one or more additional functions and, or properties.

Integral three-dimensional elements for moving objects designed as built-in parts such as furniture or cabinets in motorhomes, boats, aircraft or caravans need not be constructed according to the invention from a plurality of procured, kept or manufactured items with different requirements, but can in one piece and also from different , also combinable, materials as described above, colors, surfaces and, for example, also be provided with integrated seals and can thereby represent various functional or property-related element requirements in a three-dimensional element.

• - Wand als Raumtrenner, Halterungen für Wasserschläuche, Wasserleitungen, Waschbecken;
• - Schrankkorpus mit Dichtung, Kabelkanäle, Siphon, Halterungen für Nutzungsdinge wie Handtuchhalter oder dergleichen;
• - Duschabtrennung mitsamt Dichtung, Serviceklappe;
• - Scharniere;
• - Aufnahmen für Leuchtmittel;
• - Integrierte Dübel als Aufnahme für Zusatzteile wie beispielsweise Leuchten.

It is possible, for example, to produce a wet cell or a bath for a moving object such as a motorhome or a caravan with its multitude of elementary functions in one piece:

• - Wall as a room divider, holders for water hoses, water pipes, wash basins;
• - Cupboard body with seal, cable channels, siphon, holders for use things such as towel rails or the like;
• - Shower enclosure with seal, service flap;
• - hinges;
• - shots for bulbs;
• - Integrated dowels as a receptacle for additional parts such as lights.

• 1 ein integrales dreidimensionales Element für bewegte Objekte (1, 10) ausgeführt als Einbauteil, Korpus (20) in einer perspektivischen Ansicht mit verschiedenen integrierten Zusatzfunktionen (50) und
• 2 ein integrales dreidimensionales Element für bewegte Objekte (1, 10) ausgeführt als Einbauteil, Waschbecken (30) mit verschiedenen integrierten Zusatzfunktionen (50) und Zusatzbauteilen (70) in räumlicher Darstellung sowie
• 3 in einer dreidimensionalen Abbildung eine Einbauteilkomponente, Wandung (40) für oder als ein integrales dreidimensionales Element für bewegte Objekte (1, 10) mit verschiedenen integrierten Zusatzfunktionen (50), integrierten Eigenschaften (60) und Zusatzbauteilen (70).

In the drawings, embodiments of the invention are shown. Show it:

• 1 an integral three-dimensional element for moving objects (1, 10) designed as a built-in part, body (20) in a perspective view with various integrated additional functions (50) and
• 2 an integral three-dimensional element for moving objects (1, 10) designed as a built-in part, washbasin (30) with various integrated additional functions (50) and additional components (70) in a spatial representation and
• 3 in a three-dimensional image, a built-in component, wall (40) for or as an integral three-dimensional element for moving objects (1, 10) with various integrated additional functions (50), integrated properties (60) and additional components (70).

1 shows an integral three-dimensional element for moving objects ( 1 . 10 ) executed as a built-in part, body ( 20 ) in a perspective view with various integrated additional functions ( 50 ). The shown installation part ( 10 . 40 ) is suitable, for example, as part of a housing or a safety cover, can act as a cabinet and, or cabinet component or serve as a container for the required in moving objects technical components or utilities.

The teaching according to the invention particularly supports the realization of integrated additional functions ( 50 ) within the integral three-dimensional element for moving objects ( 1 . 10 ) by the additive manufacturing process. In the preferably integrally formed component boundary, wall, wall ( 51 ) are in the illustrated embodiment, the integrated additional functions ( 50 ) by cable channel functions ( 52 . 53 . 54 ) in one piece as well as in this example partially non-integral integrated additional functions ( 50 ) in the form of an integrated housing function, flap ( 57 ) with mounting function ( 56 ) and a filament function ( 55 ) with light ( 73 ) realized.

Not shown are the optional possibilities for the formation of integrative properties in one or more parts ( 60 ), for example, by a wall-inside honeycomb structure ( 61 ) or thread ( 61 ) as in 3 illustrated and / or the previously described materials, material combinations, surface colors, surface formations, etc. Not shown, but according to the invention additively or alternatively to the illustrated integrated additional functions ( 50 ) at least one sensor or sensor, sensors suitable for example for the detection of water, gas, acting positive or negative acceleration in accident situations or impact, movements, approximation of persons or objects, brightness or generally the light exposure situation, etc. implemented.

2 forms an integral three-dimensional element for moving objects ( 1 . 10 ) designed as a built-in part, sink ( 30 ) with various integrated additional functions ( 50 ) and additional components ( 70 ) in a spatial representation. In the context of this further exemplary embodiment, the integral three-dimensional element for moving objects (FIG. 1 . 10 . 30 ) preferably integrally integrated additional functions ( 50 ) by support functions ( 56 ) in the form of clamping elements, holder realized with the purpose of separate additional components ( 70 ) represented here by sewer, siphon ( 72 ) and, or water supply line ( 71 ).

In 2 not shown, but according to the invention additive or alternatively possible are all in 1 and or 3 illustrated integrated additional functions ( 50 ) and, or integrated properties ( 60 ) as well as the previously described materials, material combinations, surface colors, surface formations, etc.

3 illustrates in a three-dimensional illustration a built-in component, wall ( 40 ) as or for an integral three-dimensional element for moving objects ( 1 . 10 ) with various integrated additional functions ( 50 ), built-in properties ( 60 ) and additional components ( 70 ) in spatial representation. The installation component ( 40 ) can be constructed in one or more pieces and integrative component of an integral three-dimensional element ( 1 . 10 ) or be such. In the example shown, a honeycomb structure ( 61 ) core-forming between a first and at least one second wall surface ( 41 ) for a wall element (40).

In the honeycomb structure ( 61 ) or between the wall surfaces ( 41 ), an integral cable channel function ( 50 ) may be provided, for example, for a filament supply line (54, 75). At least one wall surface ( 41 ) can have built-in properties ( 60 ) by thread ( 61 ) in a one-piece manner and furthermore separate additional components ( 70 ) such as filaments ( 73 ) and, or screws ( 74 ) exhibit. Also in 3 illustrated built-in component, wall ( 40 ) for an integral three-dimensional element for moving objects ( 1 . 10 ) with various integrated additional functions ( 50 ), integrated features (60) and additional components ( 70 ) can optionally, additively and alternatively all the aforementioned integrated additional functions ( 50 ), built-in properties ( 60 ) as well as separate additional components ( 70 ) and the previously described materials, material combinations, surface colors, surface formations, etc. have.

Claims (27)

Integral three-dimensional elements (1) for moving objects comprising spatial extensions in at least two spatial directions and a non-zero extension in a third spatial direction, characterized in that additional functions (50) and, or properties (60) are implemented in an integrative manner. Integral three-dimensional elements (1) for moving objects Claim 1 , characterized in that the elements (1) are preferably built-in parts (10, 20, 30) and, or their components (40). Integral three-dimensional elements (1) for moving objects Claim 1 , characterized in that the elements (1) are formed at least in one piece. Integral three-dimensional elements (1) for moving objects Claim 1 , characterized in that the elements (1) are at least partially made by an additive manufacturing process by means of a layered workpiece structure. Integral three-dimensional elements (1) for moving objects Claim 1 , characterized in that the elements (1) consist of at least one material. Integral three-dimensional elements (1) for moving objects Claim 5 , characterized in that the at least one material can assume at least two states of aggregation. Integral three-dimensional elements (1) for moving objects Claim 1 , characterized in that the elements (1) are formed in one or more pieces. Integral three-dimensional elements (1) for moving objects Claim 7 , characterized in that the one- and, or multi-piece elements (1) consist of a first and at least a second material. Integral three-dimensional elements (1) for moving objects Claim 8 , characterized in that the one and the at least second material by a material compound and, or a Werkstoffkomposit and, or base and Einlegerelemente and, or material sections within the elements (1) are formed. Integral three-dimensional elements (1) for moving objects Claim 1 Characterized in that the integrated additional functions (50) switched on and in, or multi-piece and multi-piece or or an integrative manner in the elements (1) are implemented. Integral three-dimensional elements (1) for moving objects Claim 10 , characterized in that the integrated additional functions (50) are implemented integratively into the elements (1) by at least one wall (51). Integral three-dimensional elements (1) for moving objects Claim 10 , characterized in that the integrated additional functions (50) are implemented integratively into the elements (1) by at least one cable channel function (52, 53, 54). Integral three-dimensional elements (1) for moving objects Claim 10 , characterized in that the integrated additional functions (50) are implemented integratively into the elements (1) by at least one luminous element function (55). Integral three-dimensional elements (1) for moving objects Claim 10 , characterized in that the integrated additional functions (50) are implemented integratively into the elements (1) by at least one support function (56). Integral three-dimensional elements (1) for moving objects Claim 10 Characterized in that the integrated additional functions (50) are implemented by at least one containment function (57) integrated in the elements (1). Integral three-dimensional elements (1) for moving objects Claim 10 , characterized in that the integrated Additional functions (50) by at least one sensor, sensor integrated into the elements (1) are implemented. Integral three-dimensional elements (1) for moving objects Claim 1 , characterized in that the integrated properties (60) are implemented integrally into the elements (1) in one or more parts and / or one or more parts. Integral three-dimensional elements (1) for moving objects Claim 17 characterized in that the integrated features (60) are integrally implemented into the elements (1) by at least one honeycomb structure (61). Integral three-dimensional elements (1) for moving objects Claim 18 characterized in that the at least one honeycomb structure (61) is integrally implemented between a first and at least a second wall surface (41) of an element (1, 40). Integral three-dimensional elements (1) for moving objects Claim 17 , characterized in that the integrated features (60) are integrally implemented in the elements (1) by at least one thread (62). Integral three-dimensional elements (1) for moving objects Claim 1 , characterized in that at least one separate additional component (70) are integrally implemented in the elements (1). Integral three-dimensional elements (1) for moving objects Claim 21 , characterized in that the at least one separate auxiliary component (70) is a conduit (71, 72) for various fluids, solids and, or gases. Integral three-dimensional elements (1) for moving objects Claim 21 , characterized in that the at least one separate additional component (70) is a water supply line (71). Integral three-dimensional elements (1) for moving objects Claim 21 , characterized in that the at least one separate additional component (70) is a sewer, siphon (72). Integral three-dimensional elements (1) for moving objects Claim 21 , characterized in that the at least one separate additional component (70) is a luminaire, luminous body (73). Integral three-dimensional elements (1) for moving objects Claim 21 , characterized in that the at least one separate additional component (70) is a fastening element, screw (74). Integral three-dimensional elements (1) for moving objects Claim 21 , characterized in that the at least one separate additional component (70) is a power line (75).

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