DE102017215066A1 - Method for joining materials and components - Google Patents

Abstract

The invention relates to a method (100) for joining materials, in particular of different material classes, with a first joining step (102), wherein an open-pored structure having a first material is applied to at least a portion of a surface (12) of the first material, solid component (10) is added and with a second joining step (103), wherein a second material is at least partially added to the open-pore structure.

Description

State of the art

The invention is based on a method and a component according to the preamble of the independent claims.

In the DE 103 61 096 A1 discloses a component which is at least partially formed of metal, wherein the metallic portion is at least partially encapsulated with thermoplastic material. Furthermore, a method for producing such a component is disclosed.

Disclosure of the invention

Against this background, a method for joining materials, in particular from different material classes, and a component are presented with the approach presented here.

The method for joining materials, in particular from different material classes, comprises the following steps. In a first joining step, an open-pore structure having a first material is attached to at least a portion of a surface of a solid component having the first material. In a second joining step, a second material is added at least partially to the open-pore structure.

Joining can here be understood as meaning a preferably permanent joining of the open-pore structure to the solid component and / or the open-pore structure to the second material. Material classes can be understood as classes of materials, the respective classes having the same or similar material properties. For example, metals, ceramics or plastics can each form their own material class. Materials can also be understood here as materials. An open-pored structure can be understood as meaning a porous structure, wherein pores of the structure are at least partially in communication with each other through pore openings. An open-pore structure is characterized in particular by a low density, has a large surface area and has special mechanical properties. These include, among other things, a high elasticity, as well as a high energy absorption with mechanical or permanent, plastic deformation. In this case, a component can be understood as meaning a component or partial component or an individual part of a technical complex. A component may be, for example, a housing, a carrier, a receptacle, a holder, a shaft, a support, and / or a housing wall.

The method has the advantage that in this way both dissimilar materials and similar materials can be permanently connected to each other, wherein the forming joint compounds have a high density and high strength. In particular, in this method, a metal and a plastic, a metal and a ceramic and / or a ceramic and a plastic can be joined together. Furthermore, with this method, two identical or dissimilar metals, two identical or dissimilar ceramics and / or two identical or dissimilar plastics can be joined together. By the method thus material combinations can be realized, which can not be combined with conventional methods or only unsatisfactory, such as fluorosilicone and metals.

By forming between the first material and the second material, solid and permanent joint thus components can be realized in mixed construction. As a result, a functional extension while reducing weight and reducing costs can be achieved.

The measures listed in the dependent claims advantageous refinements and improvements of the independent claim method are possible.

It is also advantageous if, before the first joining step, the open-pored structure is adapted to the surface of the component by sawing, grinding or deformation. Sawing may in this case be understood as cutting the open-pore material or the open-pored structure, for example by a mechanical saw, a pair of scissors, a laser-beam method and / or a water-jet method. Loops of the open-pored structure can be understood as meaning, for example, a mechanical, abrasive removal of at least one partial region of the open-pored structure. By grinding can be understood, for example, a mechanical removal of a portion of a surface of the open-pored structure. Here, for example, hand-held devices such as files, rasps and / or sandpaper can be used. Furthermore, electrical or electromechanical devices, such as belt sanders, can be used. Furthermore, grinding may also be understood to mean machining of the surface of the open-pore structure by laser beams, water jets and / or sandblasting. By deforming the open-pored structure, a mechanical or plastic deformation can be understood, wherein the open-pored structure retains its new shape after deformation. The deformation can be realized, for example, by pressing the open-pore structure against the surface of the solid component to which the open-pore structure to be added. Furthermore, it is possible to press the open-pore structure against a placeholder structure or against a placeholder component, wherein the placeholder component has a same surface contour as the solid component to which the open-pore structure is to be attached.

Furthermore, it is expedient if, in the first joining step, the open-pored structure is attached to the surface of the component by soldering and / or sintering. In this way, a firm and permanent, in particular cohesive, connection between the open-pored structure and the component can be achieved.

Furthermore, it is advantageous if, in the second joining step, the second material is melted in such a way that the open-pored structure is at least partially infiltrated with the second material.

By penetrating the second material in molten form into the open-pore structure, after solidification of the second material, a tight, firm and permanent joint can be formed between the second material and the open-pored structure, and thus between the second material and the solid component. A measure of the infiltration of the second material into the open-pore structure can here be set, for example, via a temperature or a viscosity of the second material and / or via a contact pressure with which the molten second material is pressed onto the open-pored structure. The degree of infiltration furthermore depends, for example, on a pore size, a pore size distribution, a size of the pore openings, a size distribution of the pore openings and / or a wettability of a surface of the open-pore structure. A particularly dense, firm and durable connection is achieved in particular when the second material completely infiltrates the open-pored structure.

Furthermore, it is advantageous if the second material is melted by injection molding, by heat sealing and / or by ultrasonic welding. This makes it possible for the second material to be particularly effectively melted or even melted, so that the second material can infiltrate the open-pore structure particularly strongly. In particular, thermoplastic polymers or thermoplastic elastomers can be melted or melted effectively by this method.

It is furthermore advantageous if, in the second joining step, the second material is present in the form of a liquid starting material such that the open-pored structure is at least partially infiltrated with the second material. In this case, a liquid starting material may be understood as meaning, for example, short-chain, in particular liquid, monomers or oligomers which are mixed with a, in particular liquid, crosslinking agent. Furthermore, the liquid starting material can be understood as meaning a still liquid polymer which has not yet reached a gel point. As a result, the open-pored structure can be infiltrated particularly effectively and efficiently. In particular, a wetting property of the liquid starting material or of the liquid starting material can be adapted to the usability of the surface of the open-pored structure.

Furthermore, it is advantageous if the liquid starting material crosslinks after infiltration and thereby hardens. A crosslinking reaction of the liquid starting material can in this case be achieved, for example, by UV radiation or by heating or heating of the liquid starting material. In particular thermosets and elastomers can be joined by this method with the open-pore structure.

It is furthermore advantageous if the first joining step and the second joining step, essentially, take place at the same time. As a result, a speed with which the joining method is carried out can be increased.

The aforementioned advantages also apply correspondingly to a component which is produced in particular by one of the methods described above. The component has a first solid subcomponent of a first material, wherein at least partially an open-pore structure having the first material is attached to the first subcomponent, and wherein a second material is at least partially attached to the open-pored structure. This component has the advantage that for its production, no extensive pretreatment of the respective materials, as required, for example, in the bonding of two materials, is necessary. Furthermore, such a component has a high tensile and shear strength, high density and high thermal shock resistance.

Furthermore, it is advantageous if in the component or the method, the first material and / or the second material comprises a metal, a ceramic or a plastic. Because this makes it easy to produce a mixing component of one of the materials mentioned. Furthermore, this can be realized components that combine the advantages of both materials in it. Thus, on the one hand, the component can have high stability, for example due to a metal component contained therein, and on the other hand achieve a reduced weight by a plastic content.

It is also advantageous if in the component or the method, the first material comprises a metal, and the second material comprises a plastic. Because this can be realized on the one hand by the metal-related stable components, and caused by the plastic weight-reduced components. On the other hand, for example, a plastic as a second material in a simple manner to be melted or melted to infiltrate the metal, located on the metal, open-pore structure particularly effective. Since the metal usually has a much higher melting point compared to a decomposition temperature of the plastic, the plastic can be correspondingly heated and thereby melted without damaging the open-pored structure or the metallic component.

It is also advantageous if in the component or the method, the open-pore structure is designed as a felt-like structure or as a foam. A felt-like structure may be understood to mean a fibrous structure in which the fibers are joined together disorderly. The disordered joining of the fibers creates a chaotic structure, wherein the structure has a greatly enlarged surface and has different sized cavities. Since the structure is open-pored, the, in particular different sized, cavities are at least partially interconnected. As a result, the felt-like structure can be effectively infiltrated with another material, so that forms a tight, firm and permanent connection between the felt-like structure and the other material. A foam, in particular solid foam, can be understood as meaning, for example, a metal foam, a ceramic foam and / or a plastic foam. A foam offers the advantage that its properties are specifically adjustable. Thus, for example, a pore size, a pore size distribution, a size of the pore openings, a distribution of the pore size openings, a wall thickness and / or a surface condition of the pores can be set. By changing the previously enumerated parameters in the production of the foam, mechanical, electrical and / or thermal properties of the foam can advantageously be adjusted in a targeted manner. As a result, at least partially, the component contained in the foam can also be adjusted in these properties. Thus, the component can be used for example as a housing and / or hybrid component, for lightweight construction applications, or as a structural component with increased thermal conductivity, for example as a heat sink connection in power electronics.

Embodiments of the invention are illustrated in the drawings and explained in more detail in the following description.

• 1 eine schematische Darstellung eines Verfahrens zum Fügen von Materialien, insbesondere aus unterschiedlichen Materialklassen, gemäß einem Ausführungsbeispiel; sowie
• 2 ein Ablaufdiagramm eines Verfahrens gemäß einem Ausführungsbeispiel.

It shows:

• 1 a schematic representation of a method for joining materials, in particular from different classes of materials, according to an embodiment; such as
• 2 a flowchart of a method according to an embodiment.

In the following description of favorable embodiments of the present invention, the same or similar reference numerals are used for the elements shown in the various figures and similar acting, with a repeated description of these elements is omitted.

1 shows a schematic representation of a method 100 for joining materials, in particular from different material classes. Here on the left side of the figure is a section of a metal as the first material 11 having component 10 shown. At the metal 11 For example, it can be aluminum. The massive component 10 has a surface 12 on, to which another material or another component to be added.

The further component in this case has a material identical to the first material material. In an alternative embodiment of the invention, it may be provided that the further component has a material similar to the first material. Furthermore, on the left side of the figure as a metal foam 15 configured, open-pore structure shown. The open-pored metal foam 15 has different sized pores 16 and different thickness wall thicknesses 17 on.

The metal foam 15 may have been produced in a previous process step, not shown. Optionally, the metal foam 15 in a process step, also not shown, for example, by sawing, grinding and / or deformation of surface textures, in particular to the surface 12 of the massive component 10 and / or dimensions of the component 10 have been adjusted.

Optionally, in a method step not shown here, a solder 18 on a bottom 19 of mixed metal foam 15 be applied. Alternatively or additionally, the solder 18 on the surface 12 of the component 10 be applied before the metal foam 15 to the component 10 is added.

In the middle of the picture is the component 10 shown, wherein the metal foam 15 to the surface 12 of the component 10 is attached. This joining step can on the one hand by soldering the metal foam 15 with the component 10 through the lot 18 be achieved. This is where the component becomes 10 , the metal foam 15 as well as the lot 18 heated to a temperature at which the solder 18 melts and thus both with the surface 12 of the component 10 as well as by infiltration into the pores 16 of the metal foam 15 with the metal foam 15 combines. On the other hand, in an alternative embodiment, the metal foam 15 by a sintering process to the component 10 be added.

On the right side of the picture is a finished composite 30 from the component 10 , the metal foam 15 as well as one as a plastic 20 designed second material shown. The composite 30 is to be seen as a new, finished component, which is formed by two dissimilar materials. Plastic 20 can in this case in a not shown, previous process step on the metal foam 15 have been applied. By heating the plastic 20 the plastic melts 20 and infiltrated in liquid form the open-pored metal foam 15 , Depending on how strong the plastic 20 was heated, the plastic infiltrated 20 the metal foam 15 completely or only partially. The process of infiltration can be assisted by the molten plastic 20 in the metal foam 15 is pressed into it. This can be achieved for example by the fact that the plastic 20 in an injection molding process around the component 10 and the metal foam 15 or on the metal foam 15 is sprayed on. The melting of the plastic 20 may alternatively or additionally be effected by heat sealing and / or by ultrasonic welding.

Plastic 20 can be used as a separate subcomponent of the compound 30 be educated. This means that the plastic 20 not just in the pores 16 of the metal foam 15 is present, but one compared to a layer thickness of the metal foam 15 significantly greater extent in a direction perpendicular to the surface 12 of the component 10 having.

In an alternative embodiment, the metal foam 15 with a liquid starting material of the plastic 20 be infiltrated. Optionally, the liquid starting material may be mixed with a crosslinker. In a subsequent, for example, by UV radiation or initiated by heating, crosslinking step, the liquid starting material can harden to a solid plastic.

In a further alternative embodiment, it is possible that the plastic 20 in liquid form on the metal foam 15 is applied, wherein a polymerization reaction of the liquid plastic 20 has already used, but has not yet reached a gel point.

In a further, alternative embodiment it can be provided that the attachment of the metal foam 15 to the surface 12 of the component 10 as well as the attachment of the plastic 20 to the metal foam 15 essentially by infiltration takes place on a timely basis. For this purpose, for example, the solder 18 have a melting point, which substantially corresponds to the temperature for melting or melting the plastic 20 necessary is. For example, a metal foam 15 on its underside 19 and / or the component 10 on its surface 12 with the lot 18 Be provided with a solid plastic block on one of the bottom 19 of the metal foam 15 opposite side against the metal foam 15 and thus against the component 10 during a thermally induced melting of the plastic 20 at the bottom 19 pressed opposite side. This will both the metal foam 15 to the component 10 joined as well as the plastic to the metal foam 15 and thus to the component 10 together.

In an alternative embodiment it can be provided that the component 10 as well as the open-pored structure consists of ceramic material, or is constructed of a ceramic. In this case, the ceramic, open-pored structure can be infiltrated with a plastic by means of the processes described above, so that a composite of a solid ceramic component and a plastic is present. Furthermore, it may alternatively be provided that the ceramic open-pored structure is infiltrated with a molten metal. As a result, a composite of a solid ceramic component and a metal component can be achieved. The metal component may in this case only be formed as a layer or coating for the ceramic component. However, the metal component can also be designed as a solid, three-dimensional component, which is connected or joined to the ceramic component via the ceramic, open-pore structure.

In an alternative embodiment it can be provided that a solid component made of metal is attached to an open-pore structure made of metal and the open-pore structure made of metal is infiltrated by another, molten metal. As a result, for example, two identical metals can be joined together or two dissimilar metals are joined together.

In a further, alternative embodiment it can be provided that a solid component made of plastic to an open-pored structure Plastic is added and that the open-pore structure made of plastic is at least partially infiltrated by another, molten plastic. As a result, a first plastic component and a second plastic component can be connected or joined together. The infiltration of the open-pore structure made of plastic with another plastic is particularly advantageous when it comes to two different plastics with different melting temperature ranges. In particular, a melting temperature range of the plastic containing the open-pore structure should be greater than the melting temperature range of the molten plastic which infiltrates the open-pore structure of the first plastic.

In 2 is a flowchart of a method 100 shown according to an embodiment. In a first joining step 102 This is an open-pored structure of a first material on a surface 12 a massive component 10 added. The massive component 10 here also has the first material.

Optionally, in a previous manufacturing step 101 made the open-pore structure, and in particular to the surface 12 of the component 10 be adjusted. The adaptation can be done for example by sawing, grinding or plastic deformation.

After the first joining step 102 a second joining step takes place 103 in which a second material is at least partially attached to or in the open-pore structure. This can be done, for example, by fusing the second material and optionally infiltrating the open-pore structure from the first material under pressure. As a result, a dense, firm and permanent joint between both the second material and the open-pored structure of the first material as well as between the open-pore structure and the solid component 10 reached.

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 10361096 A1 [0002]

Claims (12)

Method (100) for joining materials, in particular from different material classes, with: A first joining step (102), wherein an open-pored structure comprising a first material is attached to at least a portion of a surface (12) of a solid component (10) comprising the first material; and A second joining step (103), wherein a second material is at least partially added to the open-pore structure. Method (100) according to Claim 1 , characterized in that prior to the first joining step (102) the open-pored structure is adapted to the surface (12) of the component (10) by sawing, grinding or deformation. Method (100) according to Claim 1 or 2 , characterized in that in the first joining step (102) the open-pored structure is added by soldering and / or sintering to the surface (12) of the component (10). Method (100) according to one of Claims 1 to 3 , characterized in that in the second joining step (103), the second material is melted or present in the form of a liquid starting material, that the open-pored structure is at least partially infiltrated with the second material. Method (100) according to Claim 4 , characterized in that a melting of the second material takes place by injection molding, by heat sealing and / or by ultrasonic welding. Method (100) according to Claim 4 , characterized in that the liquid starting material crosslinks after infiltration and thereby hardens. Method (100) according to one of the preceding claims, characterized in that the first joining step (102) and the second joining step (103) occur simultaneously. Component (30), in particular produced by a method (100) according to one of Claims 1 to 7 , with a first, solid subcomponent (10) made of a first material, wherein the first part component (10) at least partially an open porous structure having the first material is added, and wherein a second material is at least partially attached to the open cell structure. Component (30) after Claim 8 , characterized in that the open-pore structure is at least partially infiltrated with the second material. Component (30) or method (100) according to one of the preceding claims, characterized in that the first material and / or the second material comprises a metal (11), a ceramic or a plastic (20). Component (30) or method (100) according to one of the preceding claims, characterized in that the first material comprises a metal (10) and that the second material comprises a plastic (20). Component (30) or method (100) according to one of the preceding claims, characterized in that the open-pored structure is designed as a felt-like structure or as a foam.

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