DE102017129066A1 - A method for producing a multi-material component connection and the multi-material component connection - Google Patents

Abstract

A method for producing a multi-material component connection (130) is described. The method comprises: i) additive manufacturing of a first component (110) of a first material (150), wherein the first component (110) has a connection structure (112), ii) providing a second component (120) which has a connection section (121) having a second material (160), iii) introducing the connection portion (121) into the connection structure (112), the second material (160) being at least partially in the viscous phase, and iv) curing the second material (160) such that a positive connection (131) is formed between the first component (110) and the second component (120).

Description

Technical area

The present invention relates to the technical field of producing component connections. In particular, the present invention relates to a connection between a first component comprising a first material and a second component comprising a second material. Furthermore, in particular, the present invention relates to a method for producing a multi-material component connection, wherein a first component is produced additively. Furthermore, the present invention relates to a multi-material component connection.

Technical background

In a variety of industrial processes, such as in the automotive industry, a first component of a first material is bonded to a second component of a second material. Here, the first material and the wide material are different from each other. For example, the first material is a metal and the second material is a plastic. The result is thus a multi-material component connection, wherein the two components can be fastened to one another, for example, by way of known adhesive connections or conventional joining connections (for example, penetration, rivets, etc.). For example, for the bonding of metal and plastic in particular mainly used the gluing. Furthermore, e.g. used for the connection of aluminum and steel, the cold metal transfer (CMT) welding.

However, this raises the problem that many materials, especially materials with significantly different physical and / or chemical properties, are difficult to connect. For example, aluminum / steel connections can be realized by welding only with great effort. Classic joint connections inevitably lead to additional process steps and bring destruction of at least a portion of a material with it. Adhesive bonds are not feasible for some materials and often do not provide the required grip. Thus, adhesive bonds are often not temperature resistant or not resilient enough for the appropriate requirements. Thus, there are many cases in which a multi-material connection is to be realized, the investment cost of expenses, e.g. to implement additional process steps, but are very high. Furthermore, time is lost through the additional process steps, so that in the end higher costs and additional time consumed make it possible to combine two components made of different materials into a multi-material component connection to an expensive and lengthy process. Furthermore, in terms of durability and resilience, often the desired results are not achieved.

In summary, a multi-material component connection between a first component of a first material and a second component of a second material for a plurality of different materials can not be performed efficiently at present.

Thus, there may be a need to provide an efficient and robust method for joining a first component of a first material and a second component of a second material to a multi-material component connection for a variety of different materials, wherein a non-releasable connection is temperature resistant and resilient, provided in an efficient and reliable manner in terms of cost and time duration.

In other words, a non-detachable connection between different materials should be realized.

Summary of the invention

This need could be met by a method for producing a multi-material component connection and a multi-material component connection according to the independent claims.

Advantageous embodiments of the present invention are described by the dependent claims.

According to a first aspect of the invention, a method is provided for producing a multi-material component connection. The method comprises: i) additive manufacturing of a first component made of a first material, the first component having a connection structure, ii) providing a second component which has a connection section comprising a second material, iii) inserting the connection section in the Connection structure, wherein the second material is at least partially in the form of a viscous phase, and iv) curing of the second material such that a positive connection between the first component and the second component is formed.

The described method is based on the idea that an additively manufactured first component made of a first material and a second component made of a second material can be connected directly within a process. Thus, according to the invention, a first component is produced additively during a process for additive manufacturing. The second component may be provided to the first component without interrupting the process. In this case, a connecting portion of the second component is present at least partially as a viscous phase. As a result, the at least partially liquid or molten connection section can be introduced into a connection structure of the first component. In this case, the connection structure is designed such that the connection section can infiltrate it (eg in cavities), ie can spread around and / or into defined structures (eg of a grid). In a further step, the second material can then harden. Thus, the viscous phase solidifies or solidifies to a solid solid. The connecting portion of the second component can now be present as a solid phase, or non-viscous phase. In the region in which the connecting structure of the first component and the connecting portion of the second component are present, a positive connection can now be obtained. This is made possible by the connection section having infiltrated the connection structure. In this way, a temperature-resistant and resilient multi-material component connection, which has a positive connection between the first component and the second component, can be obtained within a process which has additive manufacturing.

The method described is efficient and robust and thus can significantly improve the efficiency and reliability of a manufacturing process in terms of cost and time. Investment costs and time can thus be saved.

Previous problems, as already described above, that in many different materials additional costly process steps are necessary and that nevertheless no temperature-resistant and resilient connections are obtained, can be overcome with the described method.

An advantage of this type of connection of dissimilar materials, e.g. Plastics and metals is the independence of additives such as adhesives. There is a pure positive engagement between the materials (e.g., plastic as the second material and metal mesh as the first material). For a variety of industrial processes, e.g. in the automotive sector, more temperature-resistant and stronger connections can be realized (a comparison offers the conventional adhesive bond). Thus, the scope of application is to be assumed at all interfaces between materials such as plastics and metal components. In addition, a compound manufactured using additive manufacturing can be applied to wall thicknesses> 0.5 mm. Furthermore, components which have the form of sheets, can be connected.

In other words, a resilient connection is made of different materials such as plastic and metal. The key mechanism of joint formation is to introduce, in particular infiltrate, the viscous phase of the second material into the interconnect structure (e.g., a metallic grid structure) of the first material. The viscous (e.g., molten) phase of the second material can perfectly fill complex cavities, undercuts, and lattice structures.

According to another aspect of the invention, a multi-material component connection is provided. The compound has a first component, which is made of a first additive material, wherein the first component has a connection structure. The connection further comprises a second component which is provided on the first component, wherein the second component has a connecting portion which has a second material. Furthermore, the connection has a positive connection, which is formed between the first component and the second component. The positive connection is in this case obtained by: i) introducing the connection section into the connection structure, wherein the second material is present at least partially as a viscous phase, and ii) curing the second material.

The described compound can be prepared by the method described above. The connection is based on the same idea as the method and can provide the same advantages as the method.

In this document, the term "additive manufacturing" may refer in particular to a process in which a component is built up layer by layer on the basis of digital 3D design data by deposition and / or solidification of solidifiable material. Additive manufacturing refers to processes for the rapid and cost-effective production of models, samples, prototypes, tools and other end products. This manufacturing takes place on the basis of computer-internal data models of informal or form-neutral material by means of chemical and / or physical processes. There are usually no special tools needed. Additive manufacturing can be divided into process engineering different methods, such as in powder bed process, open space process, liquid material process and other layer construction process. The use of these methods is economically particularly useful in the parallel production of very small components in larger quantities, for unique items, as well as the small series production or one-off production of parts with a high geometric complexity, also with additional functional integration. This is a Production process that differs from conventional, abrasive manufacturing methods. Rather than, for example, milling a component out of a solid block, additive manufacturing builds components layer by layer of solidifiable material, which is present as a fine powder, for example. In the construction in the direction of construction, physical and chemical hardening or melting processes take place.

In this document, the term "component" may refer in particular to a component or a single part of a technical complex. Here, any technical component may be referred to as a component, which together with at least one further component, ie. a second component, can be connected to a component connection. Furthermore, a plurality of components can also be connected to a component connection. A multi-material component connection comprises at least two different materials, e.g. two different metals or a metal and a plastic. However, a multi-material component connection may also comprise a plurality of different materials.

In this document, the term "connection structure" may particularly denote a structure which is suitable for connection. In particular, the term may refer to a structure which allows connection to a connecting portion which is partly in the form of a viscous phase. In this case, the connection structure can be configured such that the viscous material can be introduced into the structure and, when the viscous material hardens to a solid phase, a positive connection is created. For this purpose, the connection structure may be formed as a grid. Such allows efficient infiltration of viscous material into the clearances of the grid and provides a positive connection when the viscous material is cured. In a simple embodiment, the connection structure may be formed as a rod, hook or ball, which can be enclosed by viscous material. In a further embodiment, the connection structure may be formed as a complex lattice structure, in particular as a lattice pattern that repeats periodically in at least one spatial direction. In this case, the use of additive manufacturing is particularly advantageous because even very complex connection structures can be produced.

In this document, the term "connecting portion" may in particular denote a portion of a second component which is suitable to exist at least partially as a viscous phase. For example, the entire second component may be liquid and / or melted. Furthermore, only the connecting portion may be liquid and / or melted. The connecting portion or the whole component may e.g. be provided by injection molding.

In this document, the term "first material" may denote in particular a material which may be used for additive manufacturing. This can e.g. Metal (e.g., aluminum, steel, titanium, copper), plastic (e.g., ABS, polyamide), synthetic resin, ceramic, or a composite. The term material may include any material suitable for use in an additive manufacturing process. The material may be in powder form or, for example, as a paste. At the time of application, the material may be in a first state, and at the time of the finished component, the material may be in a second state where the material is less solid in the first state than in the second state. For this purpose, the material may initially be at least partially liquid and cure at a later time and thereby solidify. Furthermore, the material may be powdered and e.g. be solidified by means of laser energy. Furthermore, the material can be solidified by means of a binder. A plurality of further possibilities is conceivable, by means of which a corresponding first material can be obtained.

In this document, the term "second material" may denote in particular a material which may be used for insertion into a connection structure. This can e.g. also be metal (e.g., aluminum, steel, titanium, copper), plastic (e.g., ABS, polyamide), synthetic resin, ceramic, or a composite. The second material can in particular be at least partially melted, so that it is at least partially present as a viscous phase. A plurality of further possibilities are conceivable, such as a material may at least partially be present as a viscous phase.

In this document, the term "viscous phase" may denote in particular that the second material is at least partially present as a phase which has a viscosity. The viscosity refers to the viscosity or toughness of liquids and gases (fluids). The greater the viscosity, the thicker (less fluid) is the fluid; the lower the viscosity, the more fluid (flowable) it is, so it can flow faster under the same conditions. A solid body, for example, has no viscous phase or no viscosity. The second material, which is at least partially in the form of a viscous phase, can cure at a later time. For example, a liquid or an at least partially melted material to solidify or solidify. Here, the liquid or the melt has a viscosity (viscous phase), while the solid, cured body has no viscosity (no viscous phase). The viscosity can be measured in Pa (Pascal) * s (second). Some examples of viscosity are water at room temperature: 1 mPas, aluminum at 700 ° C: 2 mPas and a polymer melt: 10 ³ to 10 ¹³ mPas.

In this document, the term "positive connection" may refer in particular to the intermeshing of at least two components within a component connection. As a result, the components can not be separated from each other without or with interrupted power transmission. In a positive connection thus one component is the other component in the way, with such blocking occurs in at least one spatial direction. Some examples of positive connections include tongue and groove connection, feather key, zipper and dovetail connection. Another example is the introduction of a second material which is at least partially in the form of a viscous phase into a connecting structure of a first material which is not in the form of a viscous phase. In this case, the connection structure may be designed (for example as a grid) such that after the second material has cured, the two materials can no longer be separated from one another. The second material may cure to be in the way of the first material within the interconnect structure (e.g., within the grid) in at least one spatial direction. Thus, a positive connection can be obtained.

Embodiments of the described method and the described connection will now be explained below.

In one embodiment, the first material has a first melting point and the second material has a second melting point, wherein the first melting point is higher than the second melting point. This has the advantage that the described method can be carried out particularly efficiently.

At the moment of introduction, the second material is present at least partially in a viscous phase or in a liquid phase / melt. A viscous phase can advantageously be achieved by means of melting. In this case, the viscous phase has an elevated temperature. At the moment of introducing the viscous material in this connection structure of the first component, the connection structure is not melted. It may be advantageous if the connection structure remains in the solid state. When the first material contained in the connection structure has a higher melting point than the second material, the first material remains as a solid phase while the viscous phase of the second component is introduced. For example, the first material may be a metal and the second material may be a plastic. In this case, the melting point of the metal (approximately in the range 1000 ° C) would be significantly higher than that of plastic (approximately in the range 300 ° C). In another example, the first material may be steel (melting point about 1400 ° C) and the second material may be aluminum (melting point about 660 ° C). In this case, the first component can be additively made of steel and the aluminum can be added in a liquid without the steel being melted.

According to a further embodiment, the additive manufacturing has a 3D printing technique. This has the advantage that the method described can be integrated directly into established and proven processes. Furthermore, particularly complex connection structures can be created reliably with this method.

There are a variety of 3D printing techniques known and standardized, which may be suitable for the described method. Examples include: stereolithography, binder jetting, 3D screen printing, polyjet modeling, fused deposition modeling and laser sintering. A plurality of further possibilities is conceivable by means of which a 3D printing technique can be carried out.

According to another embodiment, a layer thickness in the additive manufacturing is in the range of 20 μm to 50 μm. This also has the advantage that the method described can be integrated directly into established and proven processes of additive manufacturing.

According to a further embodiment, the providing comprises employing an injection molding technique. This has the advantage that an established and easy to implement process can be applied directly.

The term "injection molding" may refer to a primary molding process, which can be used for example in plastics processing (thermoplastics and thermosets). In this case, the respective material is liquefied (plasticized) by means of an injection molding machine, that is, at least partially converted into a viscous phase. Then the material is introduced under pressure into an injection mold, in particular injected. Within the injection mold, the material passes by curing, for example by cooling or a crosslinking reaction, in a solid state, which has no viscous phase. Thereafter, the finished component can be removed from the injection mold. The cavity of the injection mold determines the shape and the surface structure of the component. Furthermore, the Injection mold can be attached to the connection structure of a first component, which has a first material. In this case, the connection structure and the injection mold can overlap. If a second material of a second component is then melted, it can be introduced into the injection mold and into the connection structure. The second material can harden or solidify and thereby a positive connection between the components can be obtained, in particular after the injection mold has been removed again. Injection molding can be advantageous above all for plastics, but can also be used for metals. Otherwise, a metal casting process is available for metals.

According to a further embodiment, the first material is metal, in particular steel.

According to a further embodiment, the second material is a metal, in particular aluminum, or a plastic.

These embodiments have the advantage that industrially relevant components can be manufactured and connected efficiently and flexibly. In particular, the joining of steel and aluminum, or of metal and plastic, as described above, a challenge for industrial processes, for example in the automotive industry. With the described method, these different materials can be particularly efficiently and robustly connected, by The relevance of these materials in the industry can be provided many benefits to industrial processes.

According to a further embodiment, the second material is at least partially melted during the provision. This has the advantage that the provision of the viscous phase can be carried out particularly efficiently.

There are a plurality of processes known by means of which a material can be at least partially melted. The simplest embodiment is called increasing the temperature. The process of reflow results in at least partial transfer to the liquid phase of a material. Thus, viscous properties of the material are revealed, i.e. a viscous phase is provided.

In accordance with a further exemplary embodiment, the connection structure is formed as a cavity structure, in particular as a lattice structure, furthermore in particular as a lattice pattern that periodically repeats in at least one spatial direction. This has the advantage that a particularly efficient and stable connection between the components can be provided.

Advantageously, the connection structure has at least one cavity into which the connection section of the second component can be introduced. In this way, the cavity can be filled, so that after curing a positive connection is obtained. The cavity may e.g. be provided that the connection structure is open-pored or porous. Furthermore, the cavity may be e.g. be provided by means of a grid. A grating may have grating struts oriented in two or more spatial directions and having grating crossings at the intersections of the grate struts. Between the lattice struts or between the grid cross points now arise the cavities, which can be filled with the second material. Furthermore, the grid struts and grating cross points can be enclosed by the second material. There are also many other forms conceivable, for example, a grid, which is based on the crystal structure of diamond or a honeycomb structure. The grid can be irregular or regular. In the latter case, the grating may have a grid pattern (smallest unit) which repeats periodically in one or more spatial directions.

It should be noted that embodiments of the invention have been described with reference to different subject matters. In particular, some embodiments of the invention are described with apparatus claims and other embodiments of the invention with method claims. However, it will be readily apparent to those skilled in the art upon reading this document that, unless explicitly stated otherwise, in addition to a combination of features associated with a type of subject matter, any combination of features that may result in different types of features are also possible Subject matters belong.

list of figures

• 1 zeigt ein erstes Bauteil mit einer Verbindungsstruktur gemäß einem Ausführungsbeispiel.
• 2a-c zeigen jeweils eine Multimaterial-Bauteilverbindung gemäß einem Ausführungsbeispiel.
• 3a und b zeigen jeweils eine Multimaterial-Bauteilverbindung gemäß einem weiteren Ausführungsbeispiel.
• 4a-c zeigen jeweils eine Multimaterial-Bauteilverbindung gemäß einem weiteren Ausführungsbeispiel.

Further advantages and features of the present invention will become apparent from the following exemplary description of presently preferred embodiments.

• 1 shows a first component with a connection structure according to an embodiment.
• 2a-c each show a multi-material component connection according to an embodiment.
• 3a and b each show a multi-material component connection according to a further embodiment.
• 4a-c each show a multi-material component connection according to a further embodiment.

Detailed description of exemplary embodiments

The same or similar components are provided in the figures with the same reference numerals.

According to one embodiment, the base forms the production of basic bodies (first component) with special regular lattice structures (connecting structure) by means of additive manufacturing of metallic materials (first material). A second material (secondary material, low-melting material, for example aluminum or plastics) is applied to the additive-manufactured mold by means of injection molding technology. Due to the resulting infiltration into the regular lattice structure, a positive non-detachable connection between foreign materials can be realized.

According to one exemplary embodiment, in the case of the multi-material construction, a grid structure is imprinted on a connecting structure on a first (additively manufactured) component, which in the following process step (eg injection molding process) with the first (additively manufactured) component as insert, with a second material of a second Component is infiltrated. The decisive mechanism of the connection formation is the infiltration of the second, viscous material into the advantageously metallic lattice structure of the first component. Due to the molten phase of the second material (secondary material) complex cavities, undercuts and lattice structures can be perfectly filled. The lattice structure can decrease constantly in the pulling direction in the connecting structure in order to better distribute the force transmission in the longitudinal direction.

1 shows a first component 110 made of a first material 150 , in particular metal, in particular steel, is manufactured additive. Furthermore, the first component 110 a connection structure 112 on, which also from the first material 150 is manufactured additive. The connection structure 112 is formed here as a lattice structure with periodically repeated in two spatial directions grid pattern. The lattice structure has lattice struts 114 and grid cross points 116 on.

2a to 2c each show a component connection 130 , This has the first component 110 , which consists of the first material 150 is manufactured additive, and the connection structure 112 on. Furthermore, the component connection 130 a second component 120 on, which on the first component 110 is provided, wherein the second component 120 a connection section 121 which has a second material 160 having. The second material 160 Here is a plastic. The two components 110 . 120 form a positive connection 131 out. This is obtained during a manufacturing process by: i) introducing the connection section 121 in the connection structure 112 , wherein the second material 160 at least partially present as a viscous phase, and ii) curing of the second material 160 , The introduction and curing is carried out by means of injection molding technology. The first material 150 (Steel) has a first melting point and the second material 160 (Plastic) has a second melting point, the first melting point being higher than the second melting point. The positive connection 131 passing through the connection structure 112 and the connecting section 121 is formed, is shown in different sizes. So is for 2a a special big connection structure 112 shown with many grid cross points 116 while in 2 B a medium-sized connection structure 112 , and in 2c a small connection structure 112 with few grid cross points 116 is shown. grid pursuit 114 are arranged obliquely and intersect each other at the grid cross points 116 , Between the lattice struts 114 or grid cross points 116 cavities are provided which are of the second material 160 are infiltrated. The lattice struts 114 and grid cross points 116 are from the second material 160 enclosed.

3a and 3b each show a component connection 130 as for the 2a to 2c described above. In contrast to the figures described above, the cavities of the lattice structure of the connection structure 112 designed much narrower. This is achieved by the lattice struts 114 are thinner and are provided closer together. As a result, the grid cross points 116 smaller and the cavities formed much narrower. This results in a difficult infiltration of the cavities, but also in a higher stability of the component connection 130 , For 3b is a special big connection structure 112 shown with many grid cross points 116 while in 3a a small connection structure 112 with few grid cross points 116 is shown.

4a to 4c each show a component connection 130 as for the 2a to 2c described above. In contrast to the figures described above, the cavities of the lattice structure of the connection structure 112 much further designed. This is achieved by the lattice struts 114 thicker and farther apart. This results in a simplified infiltration of the cavities, but also in a lower stability of the component connection 130 , The positive connection 131 passing through the connection structure 112 and the connecting section 121 is formed, is shown in different sizes. So is for 4a a special little connection structure 112 shown with few grid cross points 116 while in 4b a medium-sized connection structure 112 , and in 4c a big connection structure 112 with many grid points 116 is shown.

It should be noted that the term "having" does not exclude other elements or steps, and that using articles such as "a" does not exclude a plurality. Also, elements described in connection with various embodiments may be combined. It should be further noted that reference numerals in the claims should not be construed to limit the scope of these claims.

LIST OF REFERENCE NUMBERS

110

First component

112

connecting structure

114

lattice strut

116

Grid intersection

120

Second component

121

connecting portion

130

Multi-material component connection

131

Positive-locking connection

150

First material

160

Second material

Claims (10)

A method of making a multi-material component bond (130), the method comprising: additive manufacturing a first component (110) of a first material (150), wherein the first component (110) has a connection structure (112); Providing a second component (120) having a connecting portion (121) having a second material (160); Inserting the connecting portion (121) into the connecting structure (112), wherein the second material (160) is at least partially in the form of a viscous phase; and Curing the second material (160) such that a positive connection (131) is formed between the first component (110) and the second component (120). The method according to Claim 1 wherein the first material (150) has a first melting point and the second material (160) has a second melting point, the first melting point being higher than the second melting point. The method according to Claim 1 or 2 wherein the additive manufacturing comprises a 3D printing technique. The method according to Claim 3 wherein a layer thickness in the additive manufacturing is in the range of 20 μm to 50 μm. The method of any preceding claim, wherein the providing comprises employing an injection molding technique. The method of any preceding claim, wherein the first material (150) is metal, especially steel. The method of any preceding claim, wherein the second material (160) is aluminum or a plastic. The method of any one of the preceding claims, wherein the second material (160) is at least partially fused during delivery. The method according to one of the preceding claims, wherein the connection structure (112) is designed as a cavity structure, in particular as a lattice structure (114, 116), more particularly as a lattice pattern that repeats periodically in at least one spatial direction. A multi-material component connection (130) comprising: a first component (110) made of a first material (150) additively, the first component (110) having a connection structure (112); a second member (120) provided on the first member (120), the second member (120) having a connecting portion (121) having a second material (160); wherein a positive connection (131) is formed between the first component (110) and the second component (120), which is obtained by: Inserting the connecting portion (121) into the connecting structure (112), wherein the second material (160) is at least partially in the form of a viscous phase, and Curing the second material (160).

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