DE102018209282A1 - Flat element as a component, and a stack of a plurality of such flat elements and an additive manufacturing method for such a stack - Google Patents

Abstract

In order to create a flat element (100, 101) as a component, it is proposed that the flat element (100, 101) has a first upper side (10) and a second upper side (11), the first upper side (10) and the second upper side (11) are formed parallel to each other, so that a plurality of such flat elements are stackable. In order to further provide a stack (200) of a plurality of such flat elements (100, 101), it is proposed that the plurality of flat elements (100, 101) be produced in a separable stacked manner quasi-continuously, the first top side (10) being produced in each case. a first flat element (100) is at least partially in contact with the second upper side (11) of a second flat element (101). In order to further provide an additive manufacturing method for producing such a stack (200), it is proposed that the additive manufacturing method comprises at least the following steps: a. Forming a layer (41, 42) comprising particles (40), the layer (41, 42) having a surface (43, 44) parallel to the plane (20); b. after step a. Solidifying a first layer (50, 51, 52, 53) comprising particles (40) parallel to the plane (20), optionally repeating step b., Until the surface (43, 44) of the step a. reached position (41, 42) is reached; C. Repeat step a. and step b., until a stack (200) is formed, wherein preferably between the upper sides (10, 11) of two flat elements (100, 101) unconsolidated particles (40) are arranged.

Description

The invention relates to a flat element as a component, which is stackable, according to claim 1 and a stack of a plurality of such flat elements according to claim 5 and a particular additive manufacturing method for such a stack according to claim 6.

Technical area

• - ein Formschlusselement und/oder
• - ein Versteifungselement,

wobei die zumindest eine Komponente an der ersten Oberseite und an der zweiten Oberseite jeweils zweite Flächenanteile mit einer von einer Parallelebene der Flachebene des Bauteils abweichenden Ausrichtung aufweist.The invention relates to a flat element as a component, wherein the flat element has a first upper side and a second upper side, wherein the first upper side and the second upper side each have first surface portions, which are aligned parallel to a flat plane, and wherein the flat element further comprises at least one of the following Components comprising:

• - A positive connection element and / or
• a stiffening element,

wherein the at least one component on the first top side and on the second top side respectively has second surface portions with an orientation deviating from a parallel plane of the flat plane of the component.

State of the art

A flat element as a component is known for a wide variety of applications, for example in the manufacture of automobiles. For example, such a flat element is a plastic component which is used as a component for forming, for example, a housing element and / or a construction element. Such flat elements often have elevations that deviate from a flat plane and that form components which are provided as a positive-locking element and / or as a stiffening element. By means of such a positive locking element, the flat element is connectable, for example, with an adjacent component and / or attachable thereto and / or positionable in the remaining area spaced from an adjacent component. By means of a stiffening element, the rigidity of the flat element is increased compared to a purely flat shape. Both functions are combined in a single component in some embodiments.

Object of the invention

The invention is compared to the known flat elements, the task of finding a flat element, which is stackable to save space. This object is achieved by the features specified in claim 1.

Furthermore, the invention over the prior art stacks of such flat elements has the object to find a stack, which is inexpensive to produce even with a variety of flat elements and is designed to save space. This object is achieved by the features specified in claim 5.

Furthermore, the invention over the prior art additive manufacturing method for such a stack, the object is to find an additive manufacturing process in which a high part yield is achieved. This object is achieved by the features specified in claim 6.

Solution of the task

According to claim 1, the first upper side and the second upper side of the flat element are formed parallel to each other in such a way so that a plurality of such flat elements are stackable.

In accordance with claim 5, the plurality of flat elements is produced in a separable stacked quasi-continuously, wherein in each case the first upper side of a first flat element with the second upper side of a second flat element is minimally spaced. The first top side of a first flat element is only spaced by an unconsolidated particle or powder layer or a liquid or in plastic processes by a support material layer.

1. a. Bilden einer Lage umfassend Partikel, wobei die Lage eine zu der Flachebene Oberfläche aufweist;
2. b. nach Schritt a. Verfestigen einer ersten Schicht umfassend Partikel zu der Flachebene, gegebenenfalls Wiederholen von Schritt b., bis die Oberfläche der in Schritt a. gebildeten Lage erreicht ist; ;
3. c. Wiederholen von Schritt a. und Schritt b., bis ein derartiger Stapel gebildet ist.

According to claim 6, at least the following steps are provided in the additive manufacturing process:

1. a. Forming a layer comprising particles, the layer having a surface to the flat surface;
2. b. after step a. Solidifying a first layer comprising particles to the plane, optionally repeating step b., Until the surface of step a. reached situation is reached; ;
3. c. Repeat step a. and step b., until such a stack is formed.

Advantageous developments of the invention are characterized in the subclaims.

Description of the invention

• - ein Formschlusselement und/oder
• - ein Versteifungselement,

wobei die zumindest eine Komponente an der ersten Oberseite und an der zweiten Oberseite jeweils zweite Flächenanteile mit einer von einer Parallelebene der Flachebene des Bauteils abweichenden Ausrichtung aufweist.According to a first embodiment of the invention, the flat element as a component has a first top side and a second top side, wherein the first top side and the second top side each have first surface portions which are parallel to a flat plane, and wherein the flat element further comprises at least one of the following components:

• - A positive connection element and / or
• a stiffening element,

wherein the at least one component on the first top side and on the second top side respectively has second surface portions with an orientation deviating from a parallel plane of the flat plane of the component.

The flat element is primarily characterized in that the first top side and the second top side are formed parallel to one another, so that a plurality of such flat elements can be stacked on one another or in one another without loss of space. For this purpose, it is provided that each form-fitting element and each stiffening element has an alignment of the central longitudinal axes and / or the center planes so that in cooperation with a respective suitable choice of the material thicknesses of each positive-locking element and each stiffening element a virtually gapless stacking is possible.

In an advantageous embodiment, the flat element is produced by means of an injection molding process, by diecasting or by means of a milling process.

In an alternative advantageous embodiment, the flat element is produced by means of an additive manufacturing method.

In an advantageous embodiment of the flat element, particles are used as the raw material for the additive manufacturing process, which layers are successively connected to one another in layers in order to form them.

According to a further aspect, a stack of a plurality of flat elements is proposed according to an embodiment according to the above description, wherein the plurality of flat elements are made separable stacked quasi-continuously, wherein in each case the first top of a first flat element with the second top of a second flat element is minimally spaced. By using an additive manufacturing method, but also when using an injection molding process, die casting or milling process in particular the form-locking elements and the stiffening elements in their shape and in particular with respect to their material thickness are formed so that components almost without separation (using an additive manufacturing process only separated by a minimum unconsolidated particle or powder layer or a liquid or in plastic processes by a support material layer) can be superimposed.

1. a. Bilden einer Lage umfassend Partikel, wobei die Lage eine zu der Flachebene Oberfläche aufweist;
2. b. nach Schritt a. Verfestigen einer ersten Schicht umfassend Partikel zu der Flachebene, gegebenenfalls Wiederholen von Schritt b., bis die Oberfläche der in Schritt a. gebildeten Lage erreicht ist;
3. c. Wiederholen von Schritt a. und Schritt b., bis ein Stapel gebildet ist.

According to yet another aspect, an additive manufacturing method for producing a stack according to an embodiment as described above is proposed, wherein the additive manufacturing method comprises at least the following steps:

1. a. Forming a layer comprising particles, the layer having a surface to the flat surface;
2. b. after step a. Solidifying a first layer comprising particles to the plane, optionally repeating step b., Until the surface of step a. reached situation is reached;
3. c. Repeat step a. and step b. until a stack is formed.

In an advantageous embodiment of the additive manufacturing process, unconsolidated particles or powder or a liquid or, in the case of plastic processes, a support material layer are arranged between the contacting tops of two flat elements.

In an alternative advantageous embodiment of the additive manufacturing process, the adjacent upper sides of two flat elements are in direct contact with each other, ie only with solidified particles, whereby preferably two adjacent flat elements of the stack are formed free of, ie without, integral connections.

list of figures

• 1 in Draufsicht ein Flachelement mit repräsentativen Komponenten R, S und T,
• 2 in Draufsicht ein Clip-Element gemäß Detail R,
• 3 in schematischer Schnittansicht A-A das Detail R,
• 4 in schematischer Schnittansicht B-B das Detail R,
• 5 in Draufsicht eine Sicke gemäß Detail S,
• 6 in schematischer Schnittansicht C-C das Detail S,
• 7 in Draufsicht ein Positionier- und Befestigungs-Element gemäß Detail T,
• 8 in schematischer Schnittansicht D-D das Detail T,
• 9 in schematischer Schnittansicht E-E das Detail T,
• 10 in schematischer Schnittansicht F-F das Detail T,
• 11 in schematischer Schnittansicht einen Stapel aus Flachelementen in einem Partikelbecken, und
• 12 in einer schematischen schaubildlichen Darstellung eine Anordnung eines erfindungsgemäßen Flachelementes an einem weiteren Bauteil.

Embodiments of the invention are explained below with reference to the drawing. Show it

• 1 in plan view, a flat element with representative components R . S and T .
• 2 in plan view a clip element according to detail R
• 3 in a schematic sectional view AA the detail R .
• 4 in a schematic sectional view BB the detail R .
• 5 in plan view, a bead according to detail S,
• 6 in a schematic sectional view CC the detail S .
• 7 in plan view a positioning and fastening element according to detail T .
• 8th in a schematic sectional view DD the detail T .
• 9 in a schematic sectional view EE the detail T .
• 10 in a schematic sectional view FF the detail T,
• 11 in a schematic sectional view of a stack of flat elements in a particle basin, and
• 12 in a schematic perspective view of an arrangement of a flat element according to the invention on a further component.

Ordinal numbers used in the preceding and following description, unless explicitly stated to the contrary, are for the purpose of distinctness only and do not represent any order or ranking of the designated features.

Best way to carry out the invention

1 shows a first flat element 100 with exemplary arranged components R . S and T which, for example, a clip element (detail R ), a bead (detail S ) and a positioning and fastening element (detail T ) are. Alternatively or additionally, a mounting pin or the like is provided as a component. Furthermore, for example, one or a plurality of beads, dents or grooves are provided which take over, for example, supporting and / or stiffening functions. The illustrated components may also have other functions and / or other components of different shape and orientation may be provided. The flat element 100 . 101 is from the second top 11 shown in plan view, wherein the first surface portions 12 between the multitude of components R . S and T at the second top 11 the flat plane 20 define.

2 to 4 show the detail R , where in 2 the same top view as in 1 is elected, in 3 the sectional view AA as indicated in 2 and in 4 the sectional view BB as indicated in 2 is shown. In 3 and in 4 is good to see that the first top 10 and the second top 11 are identical in shape, so represent a parallel offset from each other, and only in parallel offset direction 60 (here normal to the plane plane 20 ) and constant by the amount of parallel offset 61 over the entire extent of the flat element 100 . 101 , The parallel offset direction 60 determines the inclination of a stack 200 (see 11 ). If the parallel offset direction 60 normal to the plane 20 is aligned, the stack is formed vertically. In 3 and 4 It can be seen that the component of the detail R an alignment 22 having, which inclined to the flat plane 20 and the parallel plane 21 is executed. The first area share 10 usually forms the largest area proportion of such a flat element 100 . 101 ,

In a conceivable embodiment, components interfere with the flat plane 20 deviating alignments, ie with second area shares 13 , so directly to each other, that the first area proportion 12 only formed by the transitions and the flat plane 20 through one or more of these transitions. The flat plane repeated here 20 is to be regarded only as a theoretical auxiliary plane and forms exactly like the parallel plane 21 and the orientations are not a physical part of the flat element 100 . 101 ,

The alignments 22a . 22b . 22c . 22d . 22e are exemplified in the figures as a median plane between the first top 10 and the second top 11 in the area of the respective component. The alignments 22a . 22b . 22c . 22d . 22e are to the plane level 20 almost arbitrarily inclined executable, with the alignments 22a . 22b . 22c . 22d . 22e can not be perpendicular and the steepest possible angle of a desired parallel offset direction 60 , a parallel offset amount 61 and a resulting allowed or desired material thickness and the actuation and holding forces of the clip element is dependent.

In 4 is an example (included and pointed) angle 73 the (in this detail section BB symmetrical-paired single) to the parallel offset direction 61 inclined wall, which is between the first top 10 and the second top 12 is formed. This wall is therefore at a second area proportion 13 educated. The material thicknesses 62 . 63 are chosen so that complementary shapes of the flat element are such that a distance lying on one another or a spaced apart only by an unconsolidated particle or powder layer or a liquid or in plastic processes by a support material layer formed intermediate layer is possible Aufeinanderliegen.

It is possible to use third area shares 14 provide, which no parallel correspondence on the other top side 11 respectively 10 Find. But these are only outside one investment area to one in a stack 200 (see 11 ) adjacent area element 101 . 100 arranged and form the Hinterrastfläche of the clip element, as in 3 at the projecting end of the detail R the case is.

5 and 6 show the detail S, being in 5 the same top view as in 1 and 2 is elected, and in 6 the sectional view CC as indicated in 5 is shown. In 6 is good to see that the first top 10 and the second top 11 are identical in their shape, so depicting a parallel offset from each other, and analogous to in 3 and 4 shown. Here it is clear that a round shape, even in multiple spatial rounding, for example, shell shape, the tops 10 and 11 can be represented without problems if appropriate material thicknesses are formed.

7 to 10 show the detail T, being in 7 the same top view as in 1 . 2 and 5 is elected, in 8th the sectional view DD as indicated in 7 , in 9 the sectional view EE as indicated in 7 and in 10 the sectional view FF as indicated in 7 is shown. In 8th to 10 is good to see that the first top 10 and the second top 11 are identical in their shape, so depicting a parallel offset from each other, and analogous to in 3 . 4 and 6 shown. Different shapes of the first top 10 and the second top 11 or a transition between the two tops 10 and 11 arise solely from the fact that outbreaks 15 are provided, as in 9 easy to recognize. Without an outbreak 15 would be in the area of the outbreak 15 as well as a parallel offset, so an identical contour of the first top 10 and the second top 11 , such as in 8th to see, before. In addition, arise as a result of outbreaks 15 Areas in which two adjacent flat elements 100 and 101 in a pile 200 (see 11 ) are not in contact with each other. As a result, there are third area shares 14 can be formed with a contour deviating from a pure parallel offset.

11 shows a schematic diagram of a stack 200 from (here exemplified two) flat elements, namely a (here lower) first flat element 100 and a (here upper) flat element 101 , which in large-area contact, here almost gap-free, one another. The stack 200 is (still) in a particle basin 30 arranged, in which pars pro toto some non-solidified particles 40 for an additive manufacturing process in the lower left corner are shown in an exaggerated view. The particles 40 are homogeneous or inhomogeneous in terms of size, material and shape.

The particles 40 For example, thermally or by ultraviolet radiation are solidified with each other, the energy source, for example, a corresponding light beam, preferably a laser. The particles are in the particle basin 30 in a step a. in a first location 41 introduced, which has a first surface 43 formed. Subsequently, here in several (here by way of example two) steps b. the particles 40 in the region of the first flat element 100 and the second flat element 101 solidified with each other. Incidentally, the particles remain 40 unconnected and can after completion of the additive manufacturing process of the flat elements 100 and 101 be easily separated, for example by means of pouring, shaking and / or compressed air. Preferably, these non-solidified particles 40 for the production of a next product, for example another batch 200 to be reused.

According to this in 11 The example shown is therefore initially in a first step b. a first layer 50 of particles 40 solidified according to the desired shape. Subsequently, a second layer 51 solidified accordingly and thus becomes the first surface 43 reached. Subsequently, according to a step c., If and as far as necessary and possible for generating a desired stack 200 in analogous repetition of step a. and of step b., a second layer 42 of particles 40 with a second surface 44 piled up. Then a third layer 52 and then a fourth shift 53 applied, leaving the second surface 44 or previously the uppermost point of the (here last) second flat element 101 is reached. Notwithstanding the illustrated example, in one embodiment, the number of layers 41 . 42 with the number of layers 50 to 53 identical. Alternatively, only once the particle pool 30 filled.

It should be noted that the particle pool 30 as well as one to the plane level 20 parallel surface 43 . 44 represent advantageous but not necessary embodiments only for the process control. It should also be noted that the layer orientation is not parallel to the plane of the plane 20 of the component and / or the surface of the layer must be aligned. This is based on the fact that the component can be freely rotated in space during additive manufacturing. Rather, in an alternative embodiment, the orientation of the formation of the layers 50 to 53 inclined or demand-dependent pivotable furnishings.

An exemplary additive manufacturing process, also known as additive manufacturing, is the so-called 3D printing, in particular selective laser melting (SLM) and selective laser sintering (SLS), or an application method, for example cladding or 3D powder pressure / binder jetting (BJ), Continuous Liquid Interface Production (CLIP), Electron Beam Melting (EBM) Fused Deposition Modeling (FDM). Also possible is FDM (Fused Deposition Modeling) and MJF (Multi Jet Fusion). Particle-based, liquid-based processes and processes with production from a plastic state are known. The usable materials are dependent on the respective process, but can be selected from a broader range and range from plastics to ceramics to metals, as well as material mixtures.

In a particle-based additive manufacturing process, between two adjacent flat elements according to one embodiment, particles remain between the (indirectly) contacting tops. In another embodiment, in particular when using an injection molding method, a die-casting method or a milling method, the contacting upper sides are directly in contact with each other, but not materially connected to each other. In the case of an additive manufacturing process, the energy input is spaced at such a distance from the gap to be formed between the (subsequently) contacting tops such that the energy input is just insufficient to bond the adjacent tops together, but is sufficient to Boundary) particles which form the top of the flat element to connect to the body of the respective flat element and solidify.

In 12 is an application of the flat element according to the invention 100 shown. The flat element 100 is here on a component 70 arranged, which may be formed, for example, as an aluminum component. As can be seen from the drawing, is via the fastener (detail T in 1 ) in corresponding openings 71 in the component 70 engages and over the clip element (detail R in 1 ) in corresponding openings 72 in the component 70 engages a holder of the flat element 100 on the component 70 reached.

With the flat element proposed here, a space-saving stackability of several identical flat elements is possible, thus a stack of such flat elements can be stored to save space, but at the same time individual flat elements for removal from the stack are easily separable from each other. Furthermore, such a flat element or the stack by means of an additive manufacturing process efficiently, for example, under high space utilization and particle utilization, feasible. So it is achievable a high part yield, while at the same time the manufacturing process is inexpensive feasible.

LIST OF REFERENCE NUMBERS

100

first flat element

101

second flat element

200

Stack of flat elements

10

first top

11

second top

12

first area fraction

13

second area share

14

third area share

15

outbreak

20

flat level

21

parallel plane

22

alignment

30

particle pool

40

particle

41

first location

42

second location

43

first surface

44

second surface

50

first shift

51

second layer

52

third layer

53

fourth shift

60

Parallel offset direction

61

Parallel offset amount

62

first material thickness

63

second material thickness

64

third material thickness

65

fourth material thickness

66

fifth material thickness

67

sixth material thickness

70

component

71

opening

72

opening

73

corner

Detail R

A clip member

Detail S

Beading

Detail T

Positioning and fastening element

Claims (6)

Flat element (100, 101) as a component, wherein the flat element (100, 101) has a first upper side (10) and a second upper side (11), wherein the first upper side (10) and the second upper side (11) each have first surface portions ( 12) which are aligned parallel to a plane (20), and wherein the flat element (100, 101) further comprises at least one of the following components: - a form-fitting element and / or - a stiffening element, wherein the at least one component on the first upper side (10) and on the second upper side (11) respectively second surface portions (13) with a parallel plane (21) of the flat plane (20) deviating alignment (22a, 22b, 22c, 22d, 22e), characterized in that the first top (10) and the second top (11) parallel to each other are formed, so that a plurality of such flat elements (100, 101), in particular without loss of space and / or without spacing, are stackable or stackable. Flat element (100, 101) after Claim 1 wherein the flat element (100, 101) is produced by means of an injection molding process, by means of a die casting process or by milling. Flat element (100, 101) after Claim 1 wherein the flat element (100, 101) is produced by means of an additive manufacturing method. Flat element (100, 101) after Claim 3 , wherein for the additive manufacturing process as a raw material particles (40) are used, which in order to shape in the flat plane (20) layers (50, 51, 52, 53) are interconnected in layers successively. Stack (200) of a plurality of flat elements (100, 101) according to Claim 4 , wherein the plurality of flat elements (100, 101) is manufactured quasi-continuously stackable, wherein in each case the first upper side (10) of a first flat element (100) with the second upper side (11) of a second flat element (101) is preferred (SLS ) is minimally spaced. Additive manufacturing method of flat elements, in particular according to Claim 1 to 4 , for producing a stack (200) Claim 5 wherein the additive manufacturing process comprises at least the following steps: a. Forming a layer (41, 42) comprising particles (40), the layer (41, 42) having a surface (43, 44) parallel to the plane (20); b. after step a. Solidifying a first layer (50, 51, 52, 53) comprising particles (40) parallel to the plane (20), optionally repeating step b., Until the surface (43, 44) of the step a. reached position (41, 42) is reached; ; c. Repeat step a. and step b., until a stack (200) is formed, wherein preferably between the upper sides (10, 11) of two flat elements (100, 101) unconsolidated particles (40) are arranged.

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