DE102017004106A1 - Composite material in sandwich structure with arranged on at least one cover layer printed structures and / or circuits with connection means and manufacturing method thereof - Google Patents

Abstract

Composite material in sandwich structure with two cover layers (2a, 2c) and a core (2b) arranged therebetween, wherein the composite material on at least one cover layer (2a, 2c) a printed structure and / or circuit with electronic components (6, 7) and / or Carries connecting means (5) for electrical lines, characterized in that the composite material cavities (K) which through openings (Ö) in one of the two cover layers (2a, 2c) filled with a material as an anchor (3) and through a one of the two cover layers (2a, 2c) layer applied layer (3) are interconnected and that on the layer (3) a printed structure and / or circuit (5) with electronic components (6) and / or connection means (4) for electrical lines are constructed.

Description

The invention relates, according to the preamble of patent claim 1, a composite material in sandwich structure with two outer layers and interposed core, wherein the composite material on at least one cover layer carries a printed structure and / or circuit with connection means to electrical lines. Furthermore, according to claim 5, the invention relates to a method for producing the composite material.

In the field of printed electronics ("Printed Electronics"), enormous progress has been made in recent years. The mastery of the technology allows numerous advantages such as the 3D arrangement of circuits in a confined space. Especially in the transport sector, this technology could provide both important space and the integration of new functions. The technological challenge here lies in the connection of the 3D circuit carriers to the existing power or data system. Translation of printed circuit traces to cable systems is needed. An exemplary application is in 5 shown. This is a sandwich panel, which is used in aviation as a cladding element. This element is suitable for the integration of printed structures. However, these must be connected to the existing power or data system in a subsequent process step.

For example, is from the DE 10 2014 002 365 A1 an aircraft panel for an interior of an aircraft and method for manufacturing the aircraft panel known. The aircraft panel has a sandwich structure, which as sandwich layers comprises a core section and a cover section with a prepreg layer. The core portion includes and / or is formed by a honeycomb core. For example, the honeycomb core is formed from a paper and / or cardboard material. In particular, a coated aramid paper is used for the honeycomb core. This has particular advantages in terms of a reduced weight of the aircraft panel. The optional bottom section is z. B. formed from a further prepreg layer and / or includes these. Furthermore, the aircraft panel has at least one switching element for activating at least one electrical device of the aircraft, wherein at least one switching element is fixed by the prepreg layer in the cover section. In particular, the aircraft panel comprises at least one support element for supportive support of the switching element in the aircraft panel, wherein the support element is formed as a small plate with a central recess and with peripheral edge region. Furthermore, the aircraft panel has at least one connecting line, which is electrically conductively connected to at least one switching element, wherein the at least one connecting line is covered by and / or embedded in the prepreg layer. The connecting line is electrically conductively connected to at least one switching device to a switching unit, for example, soldered. It is particularly preferred that the connection line is electrically connected to a conductor track made of copper wire before the pressing of the sandwich structure with the switching element to the switching unit. The connecting line runs below the prepreg layer and parallel or substantially parallel to the core section. Preferably, the switching unit is placed before the pressing of the sandwich structure on the lower prepreg layer and / or arranged above it. In particular, the lower prepreg layer, the switching unit and the prepreg layer are pressed together in the cover section or to the cover section. The support member rests on the core portion and / or is at least partially pressed into the core portion, in particular the support member may be formed and connected to the core portion, that the switching element is integrated equi-plane in the aircraft panel. The aircraft panel can easily be pressed to connect the individual sections and to form the sandwich structure, without damaging the switching element, as this can dodge when pressed into the central recess. The aircraft panel has a cover film, in particular a polyvinyl fluoride film (so-called Tedlar film), which is arranged on the prepreg layer and forms the visible side of the aircraft panel. The cover film is designed for insulation and / or as shock protection of the switching element. Optionally, a lacquer layer can be applied to the cover foil to improve the appearance and to protect a surface of the aircraft panel. The method for manufacturing the aircraft panel comprises the following steps: inserting at least one switching element into the cover section, indirectly or directly fixing at least one switching element via the prepreg layer in the cover section.

Furthermore, from the DE 10 2010 024 264 B4 an interior arrangement arrangement for a passenger cabin with an interior furnishing element consisting of wall cladding, window panel, side panel, ceiling cladding and luggage compartment, wherein the interior arrangement element is designed as a sandwiched component with a first cover layer, a second cover layer and a filling layer. In or on the interior device element, an electrical device and at least one line for powering the electrical device is mounted. To provide an interior device assembly with an electrical device and improved heat dissipation is a heat dissipation device present, which is formed differently from at least one line for power supply and serves to dissipate the heat generated during operation of the electrical device from the electrical device and radiation to the environment. The heat dissipation device is formed as an integral part of the interior device element and has a thermal conductivity of more than 75 W / mK. Due to the integral design of a heat removal device with the interior device element, the electrical device and / or at least one line can in the from the DE 10 2010 024 264 B4 Known interior arrangement on an additional heat sink for temperature management are omitted, which space and weight can be saved. In one embodiment, the interior device element in the region of the electrical device has at least partially thermally conductive fibers or a thermally conductive fiber-reinforced material with a high thermal conductivity. Preferably, heat-conducting fibers are woven together to form a heat-conducting textile. Preferably, the heat-conductive textile is applied to an interior device element and has a high thermal conductivity, which is greater than 75 W / mK, preferably greater than 150 W / mK. Preferably, fibers having a high thermal conductivity consist of a material which has these properties. For example, fibers of a metallic or of a graphite-containing material can be used for the fibers with a high thermal conductivity. For example, a material having a high thermal conductivity includes aluminum, copper, steel, graphite, and magnesium, respectively. In a further embodiment, an interior device element in the region of the electrical device has at least partially a coating with a high thermal conductivity. Preferably, such coatings are designed as an electrically insulating coating. An electrically insulating coating with a high thermal conductivity preferably has as a component a silicone film with or without mechanical reinforcing fibers, a plastic film, in particular polyimide, a phase-changing material, a layer of polymers or gap filler of soft elastomers with or without mechanical Reinforcement, as well as plastic films with improved thermal conductivity on. Due to the electrically insulating effect and good heat conduction, an improved interior arrangement arrangement is achieved. Preferably, a coating with high thermal conductivity as a component has an electrically non-insulating material. For example, such a material comprises aluminum, graphite, and copper as one component. An interior device element with a coating of high thermal conductivity dissipates the waste heat which is produced in a substantially point-like manner at the electrical device. Thus, the temperature of the electrical device is reduced, thereby achieving an improved interior device arrangement with cooling of the electrical device. In yet another embodiment, the interior device element has a structured surface in the region of the electrical device. Preferably, a structured surface is understood to mean a wave-like or rib-like design of the surface of the interior device element. Such a structured surface particularly increases the area for the convective delivery of heat energy and thus improves the cooling effect of the electrical device. The structured surface of the interior device element is then preferably flowed around by a cooling medium, for example by a cooling air flow, which is derived directly or indirectly from an air conditioning system of the passenger cabin. In another embodiment, the electrical device is on a metallic component which is in temperature-conducting communication with the interior device element. Preferably, this metallic component is to be understood as a fitting or hinge component, in particular a luggage compartment, a car door, a reinforcing rib or a fastening element. By such a metallic component, the surface for convective heat release from the electrical device can be increased and the temperature of the electrical device can be lowered.

Furthermore, from the EP 1 046 576 B1 a plate component, in particular for a floor panel in an aircraft known, wherein the component is substantially composed of a plurality of layers and at least one honeycomb core and at least one lower and at least one upper cover layer. For use as a floorboard in an aircraft, the cover layers are provided as lower cover layers, with the layer closest to the honeycomb core formed as a carbon fiber reinforced prepreg material layer and the underlying layer as a glass fiber reinforced prepreg material layer (gfk-pfprepreg) , Above the honeycomb core is a carbon fiber-reinforced prepreg material layer (CFRP plate) and cover layers of prepreg layers, such as fiberglass epoxy prepreg provided as an upper cover layer. Prepreg is used to describe pre-impregnated fiber material with a hardenable synthetic resin. In certain areas of the aircraft floor, especially in the door area of the aircraft, it is necessary to provide heating facilities, since it can come to -15 ° C, especially in long haul flights at high altitudes at aircraft outer skin temperatures down to - 55 ° C. For this purpose, a film heater is introduced between the upper cover layers, which preferably consists of Kapton / Cupron film heating elements is formed. Kapton is the carrier material for such heating foils, Cupron (alloy) is a heating material. Manganin can be used as an alternative fuel. Between the fiberglass epoxy prepreg layers, the film heating elements 8 are arranged and glued by means of epoxy resin layers (epoxy film adhesive). The component plate contains as top cover a heat-conducting cover plate as protection against mechanical stress and for heat distribution. Provided for this purpose is a relatively thin, about 0.5 mm thick surface-coated metal plate, preferably made of aluminum. The aluminum plate allows a fast heat transfer and a homogeneous heat distribution. The metal cover plate is glued to the other layers as a composite. For temperature control of the plate member, an electronic temperature control unit is provided which determines the temperature distribution in the plate member by means of a PTC sensor and controls the heat output of the film heater for a homogeneous temperature distribution. In case of failure of this scheme is provided to prevent overheating of the plate, an over-temperature switch with two shutdown levels. The CFRP plates and the metal cover plate are electrically connected to ground potential to ensure a safe shutdown for the short circuit, for example, in case of damage to the plate. In addition, an electronic monitoring of the heating current should be provided in the temperature control unit, so that in the event of a short circuit, the circuit is interrupted. The component plate is produced as a composite of the various layers in an autoclave at the appropriate temperature and preferably under vacuum. With the production under vacuum avoids air pockets in the component plate, which is disadvantageous for the application of the same under varying pressure conditions during use of the aircraft. The strength of the component panel, which is necessary for use as an aircraft floor panel is ensured by the structure with carbon fiber reinforced and glass fiber reinforced cover layers, the honeycomb core and the cover plate. Such a component plate has approximately a thickness of 9.5 mm. Below this composite, an approximately 10 mm thick insulating layer, for example made of plastic foam, can be arranged to reduce heat losses. For other applications with different strength requirements, the composite board can be varied in construction and layer thicknesses. In the area of a cable connection, a cable bundle is connected to the heating foil via individual cables. A connection to the measuring and switching elements is also provided. It can also be used a printed circuit, which is connected to cables of the cable bundle. Also necessary is a connection to the housing ground, ie a connection to the aluminum plate. The cable bundle is fastened by means of a cable tie on the holder of the component plate 1. For the cable connection, a corresponding free space is provided in the plate to allow the establishment of the electrical connections. A shrink tube is pulled as a protective measure over the cable bundle. After completion of the connections, the free space and a transition region between the outer surface of the plate and cable bundles are provided with a waterproof potting. The advantage here is the use of epoxy resin. Thus, a sufficient moisture-proofness and Skydrolfestigkeit is achieved. The electronic components are preferably glued to the cover plate and connected to the heating foil. In all cases, after producing a functional connection of the electrical components, the recesses may be potted with preferably epoxy resin.

Furthermore, from the EP 2 438 665 B1 a lightning protection arrangement for dissipating an electric current, the effect of lightning effect on an electronic unit briefly structurally charged flowing known, wherein the electronic unit is mounted on an aerodynamic fairing of an aircraft. Components of this lightning protection arrangement are an electrically conductive mounting plate, which is arranged on an outer side of a CFRP sandwich panel of the aerodynamic fairing, and an electrically conductive back plate, which is arranged on an inner side of the CFRP sandwich panel of the aerodynamic fairing. Furthermore, a plurality of specially installed fasteners, for example, in total with three groups of fasteners, which connect the electronic unit, the mounting plate and the back plate electrically, so that the lightning current that arises as a result of striking the mounting plate lightning and flows, is derived low impedance on the fuselage , In one embodiment of the lightning protection arrangement, the CFRP sandwich panel has at least one upper CFRP layer consisting of carbon fiber reinforced plastic, a honeycomb structured layer, in particular of resin impregnated paper, and at least one lower CFRP layer made of carbon fiber - Reinforced plastic, on. The use of CFRP sandwich panels for the aerodynamic fairing reduces the weight of the fairing and thus the weight of the aircraft. In one embodiment of the lightning protection arrangement, a wire mesh or a metal foil for protecting the CFRP sandwich panel is introduced on the outer CFRP layer of the CFRP sandwich panel in the case of possible direct impacts of a lightning strike. Since the electronic component mounted on the CFRP sandwich panel covers only a part of the CFRP sandwich panel, a braided or reticulated metal layer, which is preferably realized with a wire mesh (bronze mesh), provides lightning protection when a flash is used not the electronic component, but the remaining one Outside surface of the CFRP sandwich panel itself hits. Without the provision of the wire mesh, a lightning strike in the CFRP sandwich panel would lead to structural damage, for example to the creation of a hole in the CFRP sandwich panel. The wire mesh is therefore preferably made of a metal alloy, such as bronze. In one embodiment of the lightning protection arrangement, the mounting plate and the back plate made of a metal, which has both the known electrochemical series a small potential difference to the material of the wire mesh and the CFK and also has the lowest possible weight. Preferably, the mounting plate and the back plate made of titanium or aluminum. The electronic unit may be an antenna, for example a CRPA (control radiation pattern antenna) antenna, which has a shell made of an electrically nonconductive material, which is also called a radome. This case serves to protect the underlying actual antenna. Furthermore, the antenna has an antenna base, which consists for example of metal. At the bottom of the antenna terminal contacts are provided, which are, for example, coaxial connector. These can be contacted from the inside of an aircraft fuselage via electrical connectors. For this purpose, corresponding holes are provided in the CFRP sandwich panel which pass through the three layers of the CFRP sandwich panel. The electronic unit or the mentioned antenna is separated by a corrosion protection sealing layer on a mounting plate of the lightning protection arrangement. In the periphery of the mounting plate holes for electrically conductive screws are provided, which serve to dissipate overvoltages. Furthermore, for example, four holes may be provided to implement with four electrically conductive screws lightning protection of the antenna. These holes have, for example, a diameter of 5.2 mm. The electrically conductive screws may for example have a diameter of 4.8 mm. In one possible embodiment, the screws are passed 10 mm away from the edge of the mounting plate through the holes.

Finally, from the DE 20 2012 010 193 U1 a carbon fiber component is known, wherein in the carbon fiber component, an opening is formed which extends transversely to the surface extent and which is surrounded by a circumferential wall of the carbon fiber component. In order to present a carbon fiber component with which a low-cost and reliable way of introducing electrical currents into the carbon fiber component is possible, a contact element is provided which consists of a conductive material and which has an outer surface adapted to the peripheral wall. The contact element is exposed to a contact force with which the contact element is pressed against the circumferential wall, wherein a component of the contact force acts parallel to the surface extent of the carbon fiber component. It is possible to directly generate a contact force within the opening, which acts parallel to the surface area of the carbon fiber component. In many cases, however, it is easier to exert a force in the axial direction of the opening and to convert it into a driving force acting parallel to the surface area. The carbon fiber component may be designed for this purpose so that the peripheral wall comprises opposing wedge surfaces and that the contact element is a wedge element adapted to the wedge surfaces. An acting in the axial direction of the wedge element force is converted by the wedge surfaces in the desired contact force. Further preferably, the carbon fiber component is designed so that the opening is a conical bore and that the contact element is adapted to the conical bore cone element. There may be provided a tensioning device to put the contact element in the axial direction of the opening under tension. The cone member is slightly longer in the axial direction than the through hole, so that there is a slight projection of the cone element up and down. This ensures that the area available within the through-hole is fully utilized. At its thicker end, the cone element is provided with an electrical connection to which a cable can be connected, so that the carbon fiber component is integrated into a circuit. To improve the contact, it is also possible to provide an electrically conductive intermediate material between the contact element and the peripheral wall. The electrically conductive intermediate material is preferably softer than the carbon fiber component, so that the material deforms when the contact element in the opening is put under tension to produce the contact force. Unevenness in the surfaces can thus be compensated. The introduction of an electrically conductive intermediate material is particularly advantageous in repair processes.

The problem of connection technology is particularly evident in sensitive materials such as sandwich substrates. As also the above appreciation of the state of the art shows, differently designed sandwich panels are known. As a rule, a fixation of plug connection is difficult due to the design. Adhesive connections show only low mechanical resistance and require a further process step for connection to the printed conductor tracks. Furthermore, temperature-stressing process steps such as soldering are not possible. Finally is an adaptation of the known connection technologies for printed circuit board technology usually difficult, since known sandwich panels are not designed for a suitable anchorage.

The invention is - starting from a sandwich panel, for example according to the EP 2 438 665 B1 - The task of designing a composite material in sandwich structure such that a secure anchoring of structures and connection means, in particular for electrical lines is made possible.

This object is achieved with a composite material in sandwich structure, according to the preamble of patent claim 1, characterized in that the composite has cavities, which are filled by openings in one of the two cover layers with a material as an anchor and by a surface applied to one of the two outer layers layer is connected to each other and that on the layer, a printed structure and / or circuit is constructed with electronic components and / or connection means for electrical lines.

1. a) im Verbundwerkstoff eine Öffnung in einer der beiden Deckschichten erzeugt wird,
2. b) im Kern eine Kavität erzeugt wird,
3. c) in die Kavität oder bei einem Verbundwerkstoff mit offenzellig strukturiertem Kern ein Material als Anker gefördert wird,
4. d) die Anker in einem Druckverfahren durch eine auf einer der beiden Deckschichten flächig aufgetragenen Schicht miteinander verbunden werden, derart, dass eine reibschlüssige und/oder formschlüssige und/oder eine auf Basis der Schrumpfung beruhende Verankerung erzielt wird und
5. e) auf der Schicht eine gedruckte Struktur und/oder Schaltung ohne und mit elektronischen Komponenten und Anschlussmittel für elektrische Leitungen aufgebaut wird.

Furthermore, this object is achieved by a method for producing a composite material in sandwich structure with at least one arranged on a cover layer printed structure and / or circuit with connection means for electrical lines, according to claim 5, in which:

1. a) an opening in one of the two cover layers is produced in the composite material,
2. b) a cavity is produced in the core,
3. c) a material is conveyed into the cavity or, in the case of a composite material having an open-cell structured core, as an anchor,
4. d) the anchors are joined together in a printing process by a layer applied on one of the two cover layers, such that a frictional and / or positive and / or shrinkage-based anchoring is achieved, and
5. e) on the layer a printed structure and / or circuit is constructed without and with electronic components and connection means for electrical lines.

The invention shows a novel composite material and a manufacturing method thereof for anchoring structures on materials, in particular for connecting connecting lines for electrical lines to composite materials, such as sandwich substrates. This process is applicable to any materials which either already have cavities or in which cavities can be produced by drilling, milling or the like.

In continuation of the invention is, according to claim 2, the composite designed as a sandwich panel with honeycomb core and the opening is designed according to claim 3, for the positive connection of the armature in at least one honeycomb of the honeycomb core.

This development of the invention has the advantage that at the same time a firmly anchored, dimensionally stable connector is formed as a bridge between printed electronics and other electronic systems or cable systems.

• 1 a, b zwei Ausführungsformen eines Verbundwerkstoffes gemäß der Erfindung in Schrägansicht,
• 2 a, b eine Ausführungsform eines Sandwichsubstrats in Schrägansicht,
• 3 a, b, c eine Ausführungsform eines Volumenkörpers in Schrägansicht,
• 4 a, b, c drei Ausführungsformen für Stützstruktur, Anschlussmittel und elektronischer Komponenten bei einem Verbundwerkstoff gemäß der Erfindung in Schrägansicht und
• 5 im Detail ein Sandwichsubstrat nach dem Stand der Technik.

Further advantages and details can be taken from the following description of preferred embodiments of the invention with reference to the drawing. In the drawing shows:

• 1 a, b two embodiments of a composite according to the invention in an oblique view,
• 2 a, b an embodiment of a sandwich substrate in an oblique view,
• 3 a, b , c an embodiment of a solid in an oblique view,
• 4 a, b , c three embodiments for support structure, connection means and electronic components in a composite material according to the invention in an oblique view and
• 5 in detail, a sandwich substrate according to the prior art.

In 3a is any material / solid 1 represented, in which a cavity K is produced by a processing process (see. 3b ). These cavities K can - like 3c shows - be arbitrary shapes such as, inter alia, round, hexagonal, rectangular or the like.

Substrates or materials that already have cavities K, for example, a in 2a and 2 B illustrated sandwich substrate 2 (ie designed with two force-absorbing cover layers 2a . 2c and a core / intermediate layer 2 B , which are not accessible, are exposed by a process step punctually or areal.

The structure of the support structures by additive manufacturing processes (such as FDM (Fused Deposition Modeling)) for solids 1 (please refer 1a ) as well as for composites 2 (please refer 1b ) with cavities K, in particular as honeycomb W, show 1a and 1b , The support structures provide the necessary anchoring - the body produced 3 is dimensionally stable.

The combination of digital printing techniques for structural design, such as the FDM process and functionalization through, inter alia, selective metallization processes, such as the aerosol jet and ink-jet processes, make a multitude of applications possible. Examples of this are in 4 shown.

4a shows the structure of a connector. This becomes a conductive material 4 in the FDM structure 3 integrated. The connection 5 to the printed electronics via a printing process for selective metallization. Through this process, a firmly anchored, dimensionally stable plug connection is created as a bridge between printed electronics and other electronic systems or cable systems.

In 4b is the integration of integrated circuits 6 , or flip-chips shown here. The attachment takes place in turn by an additive generated body 5 while the contacting is given by printing method for selective metallization.

4c shows further applications for the integration of SMD / THDs, antennas, sensors, vias and other electronic components 7 ,

1) In the aviation industry, the described invention is used in cladding elements. For this substrate material / composite material 2 There are numerous possible applications, as shown below a), b), c) and d):

to a)

On the one hand, the invention can be used to generate contacting possibilities. This is the sandwich substrate 2 one-sided, ie in one of the cover plates 2a . 2c , opened with a machining process, ie generating an opening Ö (blind hole) by drilling, milling, laser or the like. After that, in an FDM process material becomes 3 into the resulting cavity K promoted (pressureless or under pressure). The resulting anchor 3 Here is both friction and form-fitting in the core 2 B attached.

Generally, every anchor structure 3 is frictionally secured. In this specific case, in addition, a positive connection can be established. This arises when the generated opening Ö is smaller than a honeycomb W.

The newly formed structures are then also with the FDM process on the substrate surface / cover layer 2a . 2c in a single molding process. Depending on the material used, this results in a further force for stabilization. During the cooling of the material processed with the FDM process, a volume shrinkage is accompanied. This volume shrinkage leads to a tensile force on the generated anchor 3 , A force is applied to the insides of the honeycomb structures W. This force action is based on the natural shrinkage of FDM-printed or other three-dimensionally printed materials which undergo shrinkage during the cooling process and thus create a mechanical anchor effect in the embodiment discussed herein. In the course of cooling from the liquid / low-viscosity state into the solid / high-viscosity state, mechanical stresses are built up in the printed structures W, which lead to an anchoring in the cavities K due to natural shrinkage forces. The volume shrinkage, in particular of the FDM thermoplastics is material-dependent (eg PC / ABS = 73.8 · 10-6 m / (mK)) and flows into the construction of the volume body 1 to achieve an optimal anchor effect; Targeted force effects can be optimized by annealing processes. FDM materials made of engineering thermoplastics ABS, polycarbonate and PPSU offer specific properties such as robustness, electrostatic dissipation, transparency, biocompatibility, UV resistance, fire protection class UL94 V-0 and FST predicates.

On the newly created area 3 can in turn in a continuous process an additive produced body / contacting 5 being constructed. Conductivity attains this / these either by the use of metallic structures, pins or the like, or by the use of electrically conductive materials which can be constructed additively.

to b)

The FDM process can also be used to build housings for electronic components or components. Applications include the integration of chips, antennas or sensors on sandwich materials 2 for the functional extension of cladding elements. A contacting of these components or their generation in the case of antennas or sensors is also by printing method for selective metallization 5 possible. A contact through the substrate 2 can by means of vias 7 which can be firmly anchored using the method.

to c)

Furthermore, it is possible to build only a solid anchorage with the method described here. Via a common interface, inter alia, snap connections plug connections or other mechatronic and also non-mechatronic functional elements can be installed. In this way, already established universal connectors can be integrated easier and faster, including sockets, USB interface or common connectors from the transport industry.

to d)

In addition to electronic components or the contacting also exist applications for the sole use of the FDM method. So are holder structures for cables with a solid anchorage 3 in the substrate 2 possible. Furthermore, support structures of the complete sandwich panel for integration into the aircraft or partial solutions for integration by means of the FDM printing process can be made possible.

2) Applications are also found in the automotive industry or in industrial sectors, which are strongly characterized by the use of metal or sheet metal (including ship and space travel). In this case, bores can be used to a frictional, positive (eg conical cavities) or based on the shrinkage induced anchorage 3 to achieve.

A support structure 3 can be created by a kind of rivet through holes in the FDM process. In this case, material is printed through the throughbore and distributed on the backside by a device located on the rear side.

The support structures 3 also become a solid composite 5 connected. The surface created by the FDM process isolates the main body.

The construction of circuits, the attachment of contacting elements or the power and data distribution is now possible. This results in completely new production possibilities, especially in the automotive industry. A substitution or partial substitution of the wiring harness in the automobile or in individual modules, such as u.a. the door is possible.

3) In the field of contacting mechatronic systems, including on-board networks arise for the production of plug-in elements new possibilities by the method described here. Through a three-dimensional structure of a plug system with direct anchoring 3 in the component is a simple design of intelligent connectors realized. A direct integration of circuit carriers, or of sensors 7 on the printed by FDM contacting element 5 is given.

In this case, individual electronic components or a composite of these can be connected to the described printing method for selective metallization in order to design the connector intelligently. Functions can i.a. the following are:

Measurement of temperature, humidity, contact wear, current / voltage for battery status detection as well as the identification of the right opponent (plug / socket), which is of great advantage especially for universally identical structures.

The method described here is valid for all components for achieving an electronic connection, including among others. Plugs and sockets.

Furthermore, the invention has hitherto not been restricted to the combinations of features defined in claims 1 and 5, but may also be defined by any other combination of specific features of all individual features disclosed overall. This means that in principle virtually every single feature of claims 1 and 5 can be omitted or replaced by at least one individual feature disclosed elsewhere in the application.

LIST OF REFERENCE NUMBERS

1

material

2

sandwich substrate

2a

first cover layer

2 B

core

2c

second cover layer

3

Anchor and structural body (FDM structure)

4

Contacting element, conductive

5

Selective metallization

6

Integrated circuits (including flip-chips)

7

electronic components (SMD / THDs, antennas, sensors, vias)

K

cavity

Ö

opening

W

Honeycomb structure (honeycomb)

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102014002365 A1 [0003]
• DE 102010024264 B4 [0004]
• EP 1046576 B1 [0005]
• EP 2438665 B1 [0006, 0009]
• DE 202012010193 U1 [0007]

Claims (8)

Composite material in sandwich structure with two cover layers (2a, 2c) and a core (2b) arranged therebetween, wherein the composite material on at least one cover layer (2a, 2c) a printed structure and / or circuit with electronic components (6, 7) and / or Carries connecting means (5) for electrical lines, characterized in that the composite material cavities (K) which through openings (Ö) in one of the two cover layers (2a, 2c) filled with a material as an anchor (3) and through a one of the two cover layers (2a, 2c) layer applied layer (3) are interconnected and that on the layer (3) a printed structure and / or circuit (5) with electronic components (6) and / or connection means (4) for electrical lines are constructed. Composite according to Claim 1 , characterized in that it is designed as a sandwich panels with honeycomb core (2b). Composite according to Claim 1 or 2 , characterized in that for the positive connection of the armature (3), the opening (Ö) in at least one honeycomb (W) of the honeycomb core (2b) is configured. Composite material according to one or more of Claims 1 to 3 , characterized in that the composite material has a via by means of vias (7). Method for producing a composite material in sandwich structure with at least one printed structure and / or circuit with electrical connection means arranged on a cover layer (2a, 2c), in which: a) an opening (Ö) is produced in the composite material in one of the two cover layers (2a, 2c), b) a cavity (K) is produced in the core (2b), c) a material is conveyed into the cavity (K) or, in the case of a composite material having an open-cell structured core (2b), as an anchor (3), d) the anchors (3) are joined together in a printing process by a layer (3) applied flat on one of the two cover layers (2a, 2c) such that a frictional, positive and / or shrinkage based anchoring (3) is achieved and e) on the layer (3) a printed circuit with electronic components (6, 7) and connection means (4) are constructed for electrical lines. Method according to Claim 5 , characterized in that sandwich panels with honeycomb core (2b) are used as the composite material. Method according to Claim 5 or 6 , characterized in that FDM materials are used. Method according to one or more of Claims 5 to 7 , characterized in that a support structure (3) in through holes (7) by a kind of rivets by the FDM process can be produced, printed through the through hole (7) material and distributed by a device located on the back surface on the back becomes.

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