DE102018119751A1 - Method and system for producing a hybrid component - Google Patents

Abstract

The invention relates to a method for producing a hybrid component, in which a tape substrate layer (14) is produced on a workpiece carrier (12) by at least one tape layer (16) by means of tape laying and then on the tape Substrate layer (14) with a tape substrate layer (14) arranged on the workpiece holder (12) via at least one 3D print head (20), a structure (36) is produced by additive application to the tape substrate layer (14) becomes.

Description

The invention relates to a method for producing a hybrid component.

The invention further relates to a system for producing a component.

From the DE 10 2015 209 571 A1 A method for producing components from fiber-plastic composites is known, in which one or more layers of at least one fiber-reinforced material with a thermoplastic matrix are arranged on a substrate or directly above, next to and / or on top of one another.

The invention has for its object to provide a method of the type mentioned, with which hybrid components can be easily automated.

This object is achieved according to the invention in the method mentioned at the outset in that a substrate tape layer is produced on a workpiece carrier by at least one tape layer by tape laying and then on the substrate tape layer with substrate arranged on the workpiece holder. Tape layer is produced via at least one 3D print head a structure by additive application to the substrate tape layer.

In the solution according to the invention, the production of a flat structure takes place via tape laminates and the production of a structure on the substrate-tape layer on the same system without removing the workpiece from the workpiece carrier, that is to say without converting the workpiece.

In this way, hybrid components can be produced in an automated manner, which are particularly complex, highly integrative and individual. For example, high demands on rigidity and strength can be met by integrating reinforcement elements in particular into the structure, which is produced using 3D printing. Light components can be manufactured; the hybrid components can be optimized in terms of shape and topology, for example. In this way, a hybrid component can be easily adapted to an occurring load case. More complex geometries can also be realized, in particular via 3D printing using the at least one 3D printing head.

In principle, the substrate tape layer produced can include underlays and be of a multi-layer design.

In one embodiment, a cover tape layer is produced on the structure by means of at least one tape layer via tape layers. A sequence of tape-layer-structure-tape-layers can thereby be achieved. In principle, the cover tape layer can also be connected to the substrate tape layer in partial areas. For example, sandwich structures can be produced in a simple manner.

In particular, it is provided that when the cover tape layer is produced, the combination of the structure and the substrate tape layer is arranged on the workpiece carrier and in particular remains on the workpiece carrier, that is to say is not implemented. This results in a simple manufacturing process, which can be carried out in particular in an automated manner.

It can further be provided that the cover tape layer is used as a substrate tape layer for a further structure applied via 3D printing. In this way, a hybrid component with a type of layer structure can be produced, which can be optimally adapted to an application.

In particular, the at least one tape layer processes a fiber-reinforced plastic tape, which in particular can be impregnated with a resin material. In particular, a flat laminate structure can be produced in this way.

In particular, the structure is produced by 3D printing a 3D printable material such as a thermoplastic material. In this way, a hybrid component with optimized adaptation to an application can be produced in a simple and optimized manner.

It can be provided that the substrate tape layer or a tape layer is heated before and / or during 3D printing. This enables a good connection between the materials to be achieved.

In particular, the substrate tape layer is heated in such a way that its surface has a temperature in the range between 260 ° C. and 400 ° C. This results in an optimized connection between the substrate-tape layer or tape layer and structure.

It is possible that the substrate tape layer or a tape layer is heated over its entire surface to be printed (for example via one or more infrared emitters), or locally at a joining zone, for example via a hot air source or laser source. In this way, an optimized connection between a tape layer and a structure can be achieved, adapted to the hybrid component to be produced.

In particular, the hybrid component is successively manufactured on the workpiece carrier by tape laying and 3D printing, the workpiece in particular not being removed from the workpiece carrier during the manufacturing process. This results in a simple, automatable feasibility of the manufacturing process.

In particular, the structure produced by 3D printing is or comprises at least one of the following: a sandwich core, a line for mass transport and / or a line for electrical current transport, a connecting element, an insert, a force introduction element, a reinforcing element, a stiffening element. In this way, optimization of the corresponding hybrid component can be achieved, adapted to an application.

In one embodiment, the workpiece carrier has a curved surface as a tool for storing tapes if the corresponding hybrid component to be produced is to have a curved surface.

According to the invention, a system of the type mentioned is provided which comprises at least one workpiece carrier, at least one tape layer and at least one 3D printing head, the workpiece carrier being a workpiece carrier for tape laying by the at least one tape layer and for the production of a Structure on a tape layer.

This means that one or more layers of tape and one or more structures can be produced on the same workpiece carrier without moving a workpiece.

In particular, the method according to the invention can be carried out with the system according to the invention or the system according to the invention can be operated with the method according to the invention.

Advantageous embodiments of the system according to the invention have already been explained in connection with the method according to the invention.

In particular, the system comprises a heating device for heating a tape layer and the application of a structure by 3D printing via the at least one 3D printing head. This enables a good material connection to be achieved.

It is expedient if the at least one tape layer and the at least one workpiece carrier are movable relative to one another. This enables a flat laminate structure to be produced in a simple manner.

It is also expedient if the at least one 3D print head and the at least one workpiece carrier are movable relative to one another and in particular are movable relative to one another in at least three axes. This enables defined structures to be created in all three spatial directions.

• 1 eine schematische Darstellung eines ersten Ausführungsbeispiels einer Anlage zur Herstellung eines Hybrid-Bauteils;
• 2 eine schematische Teildarstellung eines zweiten Ausführungsbeispiels einer Anlage zur Herstellung eines Hybrid-Bauteils;
• 3 eine schematische Ansicht eines Ausführungsbeispiels eines hergestellten Hybrid-Bauteils;
• 4 eine schematische Ansicht eines weiteren Ausführungsbeispiels eines Hybrid-Bauteils; und
• 5 eine weitere schematische Darstellung eines Hybrid-Bauteils.

The following description of preferred embodiments serves in conjunction with the drawings to explain the invention in more detail. Show it:

• 1 a schematic representation of a first embodiment of a system for producing a hybrid component;
• 2 a schematic partial representation of a second embodiment of a system for producing a hybrid component;
• 3 a schematic view of an embodiment of a manufactured hybrid component;
• 4 a schematic view of a further embodiment of a hybrid component; and
• 5 another schematic representation of a hybrid component.

An embodiment of a system according to the invention for producing a hybrid component, which in 1 shown schematically and with 10 denotes a workpiece holder 12 , The workpiece holder 12 is used to produce a tape substrate layer 14 , The tape substrate layer 14 is a tape laminate that forms a top layer.

The tape substrate layer 14 can comprise a plurality of documents which are successively arranged on one another.

The workpiece holder 12 forms a tool for storing tapes for the production of the tape-substrate layer 14 , The workpiece holder 12 can always be heated.

To make the tape substrate layer 14 is at least one tape layer 16 intended. The tape layer 16 has a multi-axis mobility, the workpiece holder 12 and the tape layer 16 are movable relative to each other. About the tape layer 16 become tape layers on the workpiece holder 12 for the production of the tape substrate layer 14 stored.

It is basically possible that the system 10 a variety of tape layers 16 includes and / or that a tape layer 16 a plurality of laying heads 18 has, over which different tapes can be deposited.

The tapes are in particular fiber-reinforced plastic tapes; these tapes can be pre-impregnated, in particular with a resin material.

The workpiece holder 12 is adapted in shape to the workpiece to be manufactured, so that a tape layer over the at least one tape layer 16 takes place close to the shape of the hybrid component to be produced.

After making the tape substrate layer 14 (of the tape laminate), a structure is created on it via additive application (3D printing). The tape substrate layer 14 which by means of the at least one tape layer 16 is the carrier for this structure. The tape substrate layer 14 remains on the workpiece holder 12 arranged, that is, to produce the structure on the tape-substrate layer 14 the corresponding workpiece is not moved and remains on the workpiece holder 12 ,

A 3D print head 20 is (at least) provided for producing the structure.

This is, for example, in a housing 22 positioned, the 3D print head 20, for example, in the housing 20 relative to the workpiece carrier 12 is mobile.

In one embodiment, the housing 22 firmly to the workpiece holder 12 and thus also firmly to the tape-substrate layer produced 14 positioned. The 3D print head 20 is then in the housing 22 relative to the tape substrate layer 14 proceed to the appropriate structure on the tape substrate layer 14 manufacture.

The structure on the tape substrate layer 14 is made using a thermoplastic material. Examples of such thermoplastic materials are the plastic materials PPS, PEEK or PA.

This material can be semi-crystalline or amorphous.

In one embodiment, it is provided that a surface 24 the tape substrate layer 14 is heated before or during the 3D printing process. In particular, it is heated to a temperature in the range between 260 ° C. and 400 ° C.

This allows the connection of the structure, which is via 3D printing on the tape substrate layer 14 is generated with the tape-substrate layer 14 improve.

It is a corresponding heating device 26 provided to the surface 24 to warm up. The heater 26 can be designed ( 1 ) that local heating of the surface 24 at a joining area 28 takes place. In particular, there is a guide on the heating device 26 provided to "hike" the joining area 28 always to ensure warming there.

For example, includes the heater 26 a hot air source or a laser source.

In an alternative embodiment ( 2 ) is a heating device 26 ' provided which a large surface area of the tape substrate layer 14 and for example the surface area of the tape substrate layer 14 which is inside the case 22 is heated up. In particular, an entire area to be printed can be heated.

In this embodiment, the heater includes 26 ' for example one or more infrared emitters 30 ,

It can have a variety of 3D print heads 20 be provided. In principle, different thermoplastic materials can also be placed on the tape substrate layer 14 be printed on.

For example, the 3D printing process for producing the structure is an FFF (Fused Filament Fabrication) process. In this method, a filament made of a thermoplastic material is heated via an extruder and then applied.

After the structure has been produced, it can be provided that a tape cover layer over the at least one tape layer on the structure 16 will be produced. To produce this tape top layer (a tape laminate), the combination of tape substrate layer previously produced is used 14 and structure especially not from the workpiece holder 12 taken.

It is possible that the tape cover layer at least in some areas on the tape substrate layer 14 is filed.

The workpiece produced in this way as a combination of tape-substrate layer, structure and tape top layer can in turn be applied to the system using a 3D printing process 10 a structure on the tape cover layer, which is then used as a tape substrate layer. A multilayer hybrid component can be produced in this way, which has the sequence tape-layer-structure-tape-layer structure, etc. The tape layers can basically have documents. You can do it different tape layers can be designed differently and different structures can be designed differently.

In 3 is a first example of a hybrid component 32 shown schematically. This hybrid component 32 can be attached to the system 10 produce. It includes a number of layers of tape 34 , between adjacent tape layers 34 one structure each 36 is produced by the at least one 3D print head 20. In the embodiment shown, the structure has 36 a continuous change in thickness in one area. This continuous change in thickness is produced by the 3D printing process using the 3D printing head 20, the position of the 3D printing head then corresponding to the respective tape substrate layer 14 according to the structure to be manufactured 36 is varied.

The first hybrid component 32 can be used, for example, in crash elements for increased energy consumption.

In 4 is a schematic embodiment of a second hybrid component 38 shown. This includes a first layer of tape 40 and a second tape layer 42 , There is a structure between them 44 manufactured. In the structure 44 is a line 46 embedded for example for a mass transfer. The structure 44 with the integrated line 46 is about the 3D printing process with the at least one 3D printing head 20 generated.

The second hybrid component 38 is also a connection element 48 provided on the second tape layer 42 by 3D printing using the 3D print head 20 is produced.

In 5 is a third embodiment of a hybrid device 50 shown. This has a sandwich structure with a first tape layer 52 , a second layer of tape 54 and a sandwich core 56 between the first layer of tape 52 and the second tape layer 54 ,

The sandwich core 56 is by means of the 3D print head 20 manufactured.

The sandwich core 56 is in particular a honeycomb core, which is printed.

The solution according to the invention makes it possible to produce hybrid components which have a structure which has, for example, a sandwich core, a line for mass transport and / or a line for electrical current transport, a connecting element, an insert, a force introduction element, a reinforcing element Stiffening element is or includes.

In the method according to the invention, a workpiece holder is used 12 (without reclamping the workpiece) a tape-laying process combined with a 3D printing process such as an FFF printing process. The number of degrees of freedom in the production of a hybrid component and in particular a lightweight structural component can thereby be increased. As a result, customized components can be produced automatically.

Through the heater 26 respectively. 26 ' the connection of tape layers and structure can be improved.

About the at least one tape layer 16 flat structures are filed, which can also include documents. Structures are produced via the at least one 3D print head 20, such structures on the tape-substrate layer produced 14 getting produced. The tape substrate layer 14 is a support layer for the structure for the component and also during the manufacturing process.

For example, force introduction points and inserts can be inserted into the structure, and optimal load transfer can be guaranteed by linking tape laying and 3D printing.

Customized hybrid components can be easily manufactured; For example, connection elements or lines such as electrical lines can be added without the system 10 needs to be converted or that new workpiece holder 12 have to be manufactured.

For example, components for small satellites can be produced in a simple and automated manner.

An automated integration of various functions into a corresponding hybrid component also results in a simple manner by appropriate process control in the production of the hybrid component in the system 10 ,

The solution according to the invention enables complex, highly integrative and individual components to be produced automatically. High demands regarding rigidity and strength can be met. This makes it possible to produce hybrid components with a low weight.

An appropriate hybrid component can be optimized in terms of shape and / or topology. Corresponding hybrid components can be effectively designed for the load cases that occur.

In the solution according to the invention is in the plant 10 and combined by the method according to the invention the laying down of fiber-reinforced (in particular impregnated) tapes and the production of a structure from a thermoplastic material.

In one embodiment, the facility 10 a monitoring device which, for example, the temperature of the heating device 26 . 26 ' or on the surface 24 monitors a cooling rate of a workpiece on the system 10 monitors etc.

In an advantageous embodiment, it is provided that a relative speed between the 3D print head 20 and the tape substrate layer 14 is in the range between 30 mm / s and 40 mm / s.

LIST OF REFERENCE NUMBERS

10

investment

12

Workpiece holder

14

Tape substrate sheet

16

Tape-Leger

18

laying head

20

3D printing head

22

casing

24

surface

26

heater

26 '

heater

28

joining area

30

infrared beam

32

First embodiment of a hybrid component

34

Tape position

36

structure

38

Second exemplary embodiment of a hybrid component

40

First tape layer

42

Second tape layer

44

structure

46

management

48

connecting element

50

Third exemplary embodiment of a hybrid component

52

First tape layer

54

Second tape layer

56

Sandwich core

QUOTES INCLUDE IN THE DESCRIPTION

This list of documents listed by the applicant has been generated automatically and is only included 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.

Patent literature cited

• DE 102015209571 A1 [0003]

Claims (16)

Method for producing a hybrid component, in which a tape substrate layer (14) is produced on a workpiece carrier (12) by at least one tape layer (16) by means of tape laying and then on the tape substrate layer ( 14) in the case of the tape substrate layer (14) arranged on the workpiece holder (12), a structure (36; 44; 56) is produced by means of additive application to the tape substrate layer (14) via at least one 3D print head (20) becomes. Procedure according to Claim 1 , characterized in that a cover tape layer is produced on the structure by at least one tape layer (16) by tape laying. Procedure according to Claim 2 , characterized in that the combination of the structure and the tape substrate layer (14) is arranged on the workpiece carrier (12) when the cover tape layer is produced. Procedure according to Claim 2 or 3 , characterized in that the cover tape layer is used as a tape substrate layer for a further structure applied via 3D printing. Method according to one of the preceding claims, characterized in that the at least one tape layer (16) processes a fiber-reinforced plastic tape. Method according to one of the preceding claims, characterized in that the structure (36; 44; 56) is produced by 3D printing. Method according to one of the preceding claims, characterized in that the tape substrate layer (14) and / or a tape layer is heated before and / or during the 3D printing. Procedure according to Claim 7 , characterized in that the tape substrate layer (14) or tape layer is heated so that a temperature in the range between 260 ° C and 400 ° C is present on its surface. Procedure according to Claim 7 or 8th , characterized in that the tape-substrate layer (14) or the tape layer is heated over its entire surface to be printed or is heated locally at a joining zone (28). Method according to one of the preceding claims, characterized in that the hybrid component on the workpiece carrier (12) is successively produced by tape laying and 3D printing, the workpiece in particular not being removed from the workpiece carrier (12) during the manufacturing process. Method according to one of the preceding claims, characterized in that the structure produced by 3D printing is or comprises at least one of the following: a sandwich core, a line for mass transport and / or a line for electrical current transport, a connection element, an insert , a force introduction element, a reinforcing element, a distribution element. Method according to one of the preceding claims, characterized in that the workpiece carrier has a curved surface. Plant for producing a hybrid component, in particular for carrying out the method according to one of the Claims 1 to 12 comprising at least one workpiece carrier (12), at least one tape layer (16) and at least one 3D printing head (20), the workpiece carrier (12) being a workpiece carrier (12) for tape laying by the at least one tape layer ( 16) and is for making a structure on a tape layer. Attachment after Claim 13 , characterized by a heating device (26; 26 ') for heating a tape layer (14) for applying a structure by 3D printing via the at least one 3D printing head (20). Attachment after Claim 13 or 14 , characterized in that the at least one tape layer (16) and the at least one workpiece carrier (12) are movable relative to one another. Plant according to one of the Claims 13 to 15 , characterized in that the at least one 3D print head (20) and the at least one workpiece carrier (12) are movable relative to one another.

Images