DE102018209282B4 - Component, as well as a stack of a plurality of such components and an additive manufacturing process for such a stack - Google Patents

Abstract

Component (100, 101), the component (100, 101) having a first upper side (10) and a second upper side (11), the first upper side (10) and the second upper side (11) each having first area portions (12) which are aligned parallel to a flat plane (20), and wherein the component (100, 101) further comprises at least one of the following components:
- A positive locking element and / or
a stiffening element, the at least one component on the first upper side (10) and on the second upper side (11) each having second surface portions (13) with an orientation (22a, 22b) that deviates from a parallel plane (21) of the flat plane (20), 22c, 22d, 22e),
wherein the first upper side (10) and the second upper side (11) are identical in shape and are formed parallel to one another, that is to say represent a parallel offset from one another
characterized in that
the parallel offset is formed only in the parallel offset direction (60) and constantly by a parallel offset amount (61) over the entire extent of the component (100, 101), the component containing one or a plurality of beads (S), dents or grooves, so that several such components (100, 101) can be stacked one on top of the other or one inside the other without loss of space and / or without space.

Description

The invention relates to a component that is stackable, as well as a stack of a plurality of such components, as claimed in claim 5, and an additive manufacturing method for such a stack, as claimed in claim 6.

Technical field

• - 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 component, the component having a first top side and a second top side, the first top side and the second top side each having first surface portions which are aligned parallel to a flat plane, and the component further comprising at least one of the following components :

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

the at least one component on the first upper side and on the second upper side each having second surface portions with an orientation deviating from a parallel plane of the flat plane of the component.

State of the art

One component is known for a wide variety of applications, for example in automobile production. For example, such a component is a plastic component, which is used as a component for forming, for example, a housing element and / or a construction element. Such components often have elevations deviating from a flat plane, which form components which are provided as a form-locking element and / or as a stiffening element. By means of such a form-locking element, the component can be connected to and / or fastened to an adjacent component, for example, and / or positioned at a distance from an adjacent component in the remaining area. By means of a stiffening element, the rigidity of the component is increased compared to a purely flat shape. In some embodiments, both functions are combined in a single component.

From the WO 2016/030405 A1 a 3D printer, a 3D printer arrangement and a generative manufacturing method are known. According to the summary, a 3D printer (100) is described, which is set up to build up a three-dimensional component in layers by forming superimposed layers of particulate building material and selectively solidifying a partial area of the respective building material layer. The 3D printer (100) is set up to simultaneously in a first installation space (B 1), which is arranged in the 3D printer, one or more first three-dimensional components and in a second installation space (B2), which is adjacent to the first Installation space with a horizontal distance from it is arranged in the 3D printer to build up one or more second three-dimensional components.

The state of the art is also DE 20 2013 005 102 U1 known.

Object of the invention

Compared to the previously known components, the invention is based on the object of finding a component which can be stacked in a space-saving manner. This object is achieved by the features specified in claim 1.

Furthermore, compared with the previously known stacks of components of this type, the invention is based on the object of finding a stack which can also be produced inexpensively with a large number of components and is designed to save space. This object is achieved by the features specified in claim 5.

Furthermore, compared with the previously known additive manufacturing processes for such a stack, the invention is based on the task of finding 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 component are formed parallel to one another in such a way that a plurality of such components can be stacked one inside the other.

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 wobei zwischen den Oberseiten (10, 11) von zwei Bauteilen (100, 101) unverfestigte Partikel (40) angeordnet sind.

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

1. a. Forming a layer comprising particles, the layer having a surface facing the flat plane;
2. b. after step a. Solidifying a first layer comprising particles to the flat plane, optionally repeating step b., Until the surface of the in step a. formed position is reached; ;
3. c. Repeating step a. and step b. until such a stack is formed, with between the tops ( 10th , 11 ) of two components ( 100 , 101 ) unsolidified particles ( 40 ) are arranged.

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 component has a first upper side and a second upper side, the first upper side and the second upper side each having first surface portions which are aligned parallel to a flat plane, and the component furthermore having at least one of the following components :

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

the at least one component on the first upper side and on the second upper side each having second surface portions with an orientation deviating from a parallel plane of the flat plane of the component.

The component is primarily characterized in that the first upper side and the second upper side are formed parallel to one another, so that a plurality of such components can be stacked on one another or in one another without loss of space. For this purpose, it is provided that each interlocking element and each stiffening element has an alignment of the central longitudinal axes and / or the central planes such that, in cooperation with a suitable choice of the material thicknesses of each interlocking element and each stiffening element, an almost spaceless stacking is possible.

In an advantageous embodiment, the component is produced by means of an injection molding process, by means of a die casting process or by means of a milling process.

In an alternative advantageous embodiment, the component is manufactured by means of an additive manufacturing process.

In an advantageous embodiment of the component, particles are used as raw material for the additive manufacturing process, which particles are connected to one another in layers for shaping in layers to the flat plane.

According to a further aspect, a stack of a plurality of components is proposed in accordance with an embodiment in accordance with the above description, the plurality of components being stacked so as to be separable, quasi-continuously, the first top side of a first component being in each case with the second top side of a second component is minimally spaced. Through the use of an additive manufacturing process, but also when using an injection molding process, a die casting process or a milling process, the form-locking elements and the stiffening elements in particular are designed in their shape and in particular with regard to their material thickness in such a way that components are almost completely spaced (when using an additive manufacturing process only separated by a minimal unconsolidated particle or powder layer or a liquid or, in the case of plastic processes, a support material layer) can be placed on top of one another.

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 wobei zwischen den Oberseiten (10, 11) von zwei Bauteilen (100, 101) unverfestigte Partikel (40) angeordnet sind.

According to one aspect of the invention, an additive manufacturing method for manufacturing a stack according to an embodiment as described above is proposed, the additive manufacturing method comprising at least the following steps:

1. a. Forming a layer comprising particles, the layer having a surface facing the flat plane;
2. b. after step a. Solidifying a first layer comprising particles to the flat plane, optionally repeating step b., Until the surface of the in step a. formed position is reached;
3. c. Repeating step a. and step b. until a stack is formed with between the tops ( 10th , 11 ) of two components ( 100 , 101 ) unsolidified particles ( 40 ) are arranged.

In an alternative advantageous embodiment of the additive manufacturing process, the adjacent top sides of two components are in direct contact with one another, that is to say only with solidified particles, two adjacent components of the stack preferably being formed free of, that is to say without, integral connections.

Figure list

• 1 in Draufsicht ein Bauteil 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 Bauteilen in einem Partikelbecken, und
• 12 in einer schematischen schaubildlichen Darstellung eine Anordnung eines erfindungsgemäßen Bauteiles an einem weiteren Bauteil.

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

• 1 a top view of a component with representative components R , S and T ,
• 2nd in plan view a clip element according to detail R ,
• 3rd in a schematic sectional view AA the detail R ,
• 4th in a schematic sectional view BB the detail R ,
• 5 in plan view a bead according to the 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 ,
• 10th in a schematic sectional view FF the detail T ,
• 11 a schematic sectional view of a stack of components in a particle pool, and
• 12th a schematic diagram of an arrangement of a component according to the invention on another component.

Unless explicitly stated to the contrary, ordinal numbers used in the preceding and subsequent description serve only to clearly distinguish them and do not reflect the order or order of the features described.

Best way to carry out the invention

1 shows a first component 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. As an alternative or in addition, a mounting pin or the like is also provided as a component. Furthermore, for example, one or a plurality of beads, dents or grooves are provided, which take over, for example, load-bearing and / or stiffening functions. The components shown can also have other functions and / or further components of different shape and orientation can be provided. The component 100 , 101 is from the second top 11 shown in plan view, with the first surface portions 12th between the multitude of components R , S and T on the second top 11 the flat plain 20th define.

2nd to 4th show the detail R, wherein in 2nd the same top view as in 1 is chosen in 3rd the sectional view AA according to the marking in 2nd and in 4th the sectional view BB according to the marking in 2nd is shown. In 3rd and in 4th can be seen well that the first top 10th and the second top 11 are identical in shape, that is to say they represent a parallel offset from one another, and only in the parallel offset direction 60 (here normal to the flat plane 20th ) and constant around the parallel offset amount 61 over the entire extent of the component 100 , 101 . The parallel offset direction 60 determines the slope of a stack 200 (compare 11 ). If the parallel offset direction 60 normal to the flat plane 20th is aligned, the stack is vertical. In 3rd and 4th it can be seen that the component of the detail R an alignment 22 which is inclined to the flat plane 20th and the parallel plane 21 is executed. The first area share 10th usually forms the largest area share of such a component 100 , 101 .

In one conceivable embodiment, components also delimit from the flat plane 20th deviating orientations, i.e. with second areas 13 , so close together that the first area share 12th is formed only by the transitions and the flat plane 20th is to pass through one or more of these transitions. The flat plane repeatedly mentioned here 20th is only to be regarded as a theoretical auxiliary level and forms just like the parallel level 21 and the orientations are not a physical part of the component 100 , 101 .

The alignments 22a , 22b , 22c , 22d , 22e are exemplary in the figures as a central plane between the first upper side 10th and the second top 11 shown in the area of the respective component. The alignments 22a , 22b , 22c , 22d , 22e are to the flat level 20th almost any incline, the orientations 22a , 22b , 22c , 22d , 22e cannot be vertical and the steepest possible angle from a desired parallel offset direction 60 , a parallel offset amount 61 and a resulting permitted or desired material thickness and the actuating and holding forces of the clip element is dependent.

In 4th is an example of a (enclosed and acute) angle 73 the (in this detail section BB symmetrically paired only) to the direction of parallel offset 61 inclined wall, which is between the first top 10th and the second top 12th is formed. So this wall is with a second area share 13 educated. The material thickness 62 , 63 are selected so that complementary forms of the component result in such a way that they can lie one on top of the other without spacing or one that is spaced apart by an unconsolidated particle or powder layer or a liquid or, in the case of plastic processes, by a support material layer.

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

5 and 6 show the detail S , where in 5 the same top view as in 1 and 2nd is selected, and in 6 the sectional view CC as marked in 5 is shown. In 6 can be seen well that the first top 10th and the second top 11 are identical in shape, that is, they represent a parallel offset from each other, in the same way as in 3rd and 4th shown. Here it becomes clear that a round shape, also in multiple spatial rounding, for example shell shape, of the upper sides 10th and 11 can be mapped without problems if appropriate material thicknesses are formed.

7 to 10th show the detail T , where in 7 the same top view as in 1 , 2nd and 5 is chosen in 8th the sectional view DD as marked in 7 , in 9 the sectional view EE as marked in 7 and in 10th the sectional view FF as marked in 7 is shown. In 8th to 10th can be seen well that the first top 10th and the second top 11 are identical in shape, that is, they represent a parallel offset from each other, in the same way as in 3rd , 4th and 6 shown. Different shapes of the first top 10th and the second top 11 or a transition between the two tops 10th and 11 arise solely from that outbreaks 15 are provided as in 9 is easy to see. Without an outbreak 15 would be in the area of the outbreak 15 also a parallel offset, i.e. an identical contour of the first upper side 10th and the second top 11 , such as in 8th to see before. In addition, arise as a result of the outbreaks 15 Areas in which two adjacent components 100 and 101 in a stack 200 (compare 11 ) are not in contact with each other. As a result, there are third areas 14 can be formed with a contour that deviates from a pure parallel offset.

11 shows in principle a stack 200 from (shown here by way of example two) components, namely a (lower here) first component 100 and a (here upper) component 101 , which are in large-scale contact, here almost gap-free, on top of each other. The stack 200 is (still) in a particle pool 30th arranged, in which pars pro toto some unsolidified particles 40 for an additive manufacturing process are shown in the lower left corner in an exaggerated representation. The particles 40 are homogeneous or inhomogeneous in terms of size, material and shape.

The particles 40 are, for example, thermally solidifiable or by means of ultraviolet radiation, the energy source being, for example, a corresponding light beam, preferably a laser. The particles are in the particle pool 30th in a step a. in a first position 41 introduced which is a first surface 43 trains. Subsequently, in several steps (here two examples) b. the particles 40 in the area of the first component 100 and the second component 101 solidified together. Otherwise the particles remain 40 disconnected and can be removed from the components after completing the additive manufacturing process 100 and 101 can be easily separated, for example by means of pouring, shaking and / or compressed air. These non-solidified particles can preferably 40 for the production of a next product, for example another stack 200 , be reused.

According to this in 11 The example shown is first b. a first layer 50 of particles 40 solidified according to the desired shape. Then a second layer 51 solidified accordingly and thus the first surface 43 reached. Then, according to a step c., If and as far as necessary and possible, for the generation of a desired stack 200 , in an analogous repetition of step a. and step b., a second layer 42 of particles 40 with a second surface 44 heaped up. Then a third layer 52 and then a fourth shift 53 applied so that the second surface 44 or previously the top position of the (here last) second component 101 is reached. In one embodiment, the number of layers deviates from the illustrated example 41 , 42 with the number of layers 50 to 53 identical. Alternatively, the particle pool is used only once 30th filled.

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

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

In a particle-based additive manufacturing process, according to one embodiment, particles remain between two adjacent components between the (indirectly) contacting upper sides. In another embodiment, in particular when using an injection molding process, a die casting process or a milling process, the upper sides in contact are in direct contact with one another, but are not integrally connected to one another. 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 (after) contacting upper sides that the energy input is just not sufficient to connect the adjacent upper sides to one another, but is sufficient to ( Boundary) particles, which form the top of the component, to connect and solidify with the body of the component in question.

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

With the component proposed here, a space-saving stackability of several identical components is made possible, so a stack of such components can be stored in a space-saving manner, but at the same time individual components can be easily separated from one another for removal from the stack. Furthermore, such a component or the stack can be carried out efficiently by means of an additive manufacturing process, for example with high space utilization and particle utilization. A high yield of parts can thus be achieved, while at the same time the manufacturing process can be carried out inexpensively.

Reference list

100

first component

101

second component

200

Stack of components

10th

first top

11

second top

12th

first area share

13

second area share

14

third area share

15

outbreak

20th

Flat plain

21

Parallel plane

22

Alignment

30th

Particle basin

40

particle

41

first layer

42

second layer

43

first surface

44

second surface

50

first layer

51

second layer

52

third layer

53

fourth layer

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

angle

Detail R

Clip element

Detail p

Surround

Detail T

Positioning and fastening element

Claims (6)

Component (100, 101), the component (100, 101) having 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 flat plane (20), and wherein the component (100, 101) further comprises at least one of the following components: - a form-locking element and / or - a stiffening element, the at least one component on the first upper side (10) and on the second upper side (11) each having second surface portions (13) with one that deviates from a parallel plane (21) of the flat plane (20) Alignment (22a, 22b, 22c, 22d, 22e), wherein the first upper side (10) and the second upper side (11) are identical in shape and are formed parallel to one another, that is to say represent a parallel offset from one another, characterized in that the parallel offset is formed only in the parallel offset direction (60) and constantly by a parallel offset amount (61) over the entire extent of the component (100, 101), the component being one or an M Contains number of beads (S), dents or grooves, so that several such components (100, 101) can be stacked on top of one another or into one another without loss of space and / or without space. Component (100, 101) after Claim 1 , The component (100, 101) being produced by means of an injection molding process, by means of a die casting process or by milling. Component (100, 101) after Claim 1 , The component (100, 101) being manufactured by means of an additive manufacturing process. Component (100, 101) after Claim 3 The raw material used for the additive manufacturing process is particles (40), which are connected to one another in layers for shaping in layers (50, 51, 52, 53) to the flat plane (20). Stack (200) from a plurality of components (100, 101) after Claim 4 . Additive manufacturing process of components, especially after Claim 1 to 4th , to produce a stack (200) according to Claim 5 , wherein 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 flat plane (20); b. after step a. Solidifying a first layer (50, 51, 52, 53) comprising particles (40) parallel to the flat plane (20), optionally repeating step b. Until the surface (43, 44) of the in step a. formed position (41, 42) is reached; c. Repeating step a. and step b. until a stack (200) is formed; wherein non-solidified particles (40) are arranged between the top sides (10, 11) of two components (100, 101).

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