DE102020121354A1 - Method for manufacturing a composite component and introducing a predetermined breaking point in the composite component and a composite component - Google Patents

Abstract

The invention relates to a method for manufacturing a composite component and introducing a predetermined breaking point in the composite component, wherein the manufactured composite component has a first component made of a first material and a second component made of a second material, and the first material and the second material have different material properties. with the following steps:- introducing and/or applying a structure in and/or on the first material by means of a laser by acting in and/on the first material in such a way that a first undercut with a blockage is formed on a first side of the structure and a second side of the structure opposite the first side is free of an undercut or has a second undercut, the second undercut having a lower blockage than the first undercut, and- joining the first material and the second material and surrounding and/or filling d he structure through the second material under the influence of heat, so that the manufactured composite component is present with a predetermined breaking point when a directed force acts in a direction deviating from the blocking of the first undercut. The invention also relates to a composite component having two different materials.

Description

The invention relates to a method for manufacturing a composite component and introducing a predetermined breaking point in the composite component, wherein the manufactured composite component has a first component with a first material and a second component with a second material, and the first material and the second material have different material properties. Furthermore, the invention relates to a composite component having two different materials.

Composite components are usually used in lightweight construction. To produce a composite component, for example, a metal component or a ceramic component is connected to a plastic component. The connection between these two connection partners is realized, for example, materially by gluing or positively and non-positively by screwing. In the case of a slide with a plastic seat and metal runners, there is a risk that the screw connection will break out of the plastic seat unintentionally under load. In the event of an adhesive bond, the flat bonded connection between the runners and the underside of the plastic seat can also break unintentionally. In addition, the mechanical properties of the bond are often temperature-dependent and the adhesive only has limited thermal and/or chemical resistance.

Gluing as a joining method and screwing both have the disadvantage that an additional connection means (adhesive, screws and nuts) and tools as well as a complex preparation of the surfaces to be connected and, if necessary, a curing time must be observed.

The object of the invention is to improve the prior art.

The object is achieved by a method for manufacturing a composite component and introducing a predetermined breaking point in the composite component with the features according to claim 1. Further advantageous embodiments of the method are described in dependent claims 2 to 9. Furthermore, the object is achieved by a composite component having two different materials according to claim 10.

Thus, a method is provided in which a targeted, direction-oriented introduction and / or application of a structure in the surface of a first component, in particular a solid material such as metal or ceramic, a targeted blocking in the connection of the first component with a second component, in particular made of plastic and/or a thermoplastic. In this case, the first component and/or first material and the second component and/or second material are connected by surrounding and/or filling the integrated and/or applied structure with the second material.

Because a first undercut and/or a second undercut of the structure is filled in and/or surrounded by the second material, in particular a thermoplastic, a targeted, direction-oriented blockage is formed by the first undercut at the same time. In this case, under the effect of heat, the thermoplastic flows, for example, into a depression and thus an undercut and/or surrounds an elevation of the structure of the first material.

Due to the fact that the first undercut is only deliberately applied and/or applied to one side of the structure under the action of the laser, a predetermined breaking point is simultaneously formed on the opposite side of the structure when the two materials and/or components are connected, which breakage point occurs when a directed, in particular one-dimensional linear force in a direction deviating from the direction of blocking the first undercut can be broken.

Thus, a predetermined breaking point or several predetermined breaking points are created, which break in a direction-oriented manner only in the case in which a defined, predetermined and direction-dependent force is applied to the composite component and/or an object in which the composite component is used, in particular only in the case of danger and/or emergency.

An essential idea of the invention is based on the fact that a structure is introduced into a solid first material and/or component by means of a laser, which is designed differently on opposite sides and has at least one undercut, so that a directional orientation is thereby introduced, and under the influence of heat a second, in particular thermoplastic, material, the first and second materials are then joined, with the structure being filled out and/or surrounded by the second material and thus the undercut, as a result of which a form fit is brought about due to a blockage by the first undercut, so that when force is applied there is a targeted, direction-oriented predetermined breaking point in a direction other than the blocking direction.

In particular, the structure can be introduced or embossed by using porous materials, as is the case for example wise during sintering or by 3D printing or by means of 3D printed parts. In particular, one material has a higher melting point than the other material. The first material and the second material can also each be plastics with different melting temperatures.

It is particularly advantageous if a plurality of structures and thus predetermined breaking points are incorporated and/or applied to and/or in the first material, since this enables a two-dimensional, direction-dependent interlocking of the first material with the second material. In this case, the structures introduced by means of the laser in and/or on the first material can be spaced evenly apart in order to enable breaking along the entire connection surface when a corresponding force is applied. The structures can also be arranged unevenly, so that in a region of the first material with fewer structures, the predetermined breaking points break first when a corresponding force is applied, and only then does a region with a higher density of the introduced and/or applied structures break. A targeted, gradual breaking of the predetermined breaking points during use can reduce the risk of injury to the user of the sled in an emergency, for example in the case of sports equipment such as a sled.

Direction-dependent interlocking of the first material and/or component and the second material and/or component is achieved in particular in that the laser for laser cutting strikes the surface of the first material at an angle, thereby creating a depression and undercut and/or by raising the first material at the point of impact, so-called volcanic ejection, an elevation is generated.

Consequently, a surface, direction-dependent interlocking and connecting the two materials under the action of heat and the flow of the second material and thereby filling the depression and thus the undercut of the structure and/or surrounding an elevation and thus the undercut of the structure result in a form-fitting and/or material-to-material connection connection created.

It is particularly advantageous that microstructuring and thus microinterlocking is produced between the first material and the second material, with the depth and/or height of the structure being in particular in a range from 50 μm to 500 μm. This ensures that only the outer surface of the first material is processed using the laser and the action of the laser cannot lead to unwanted cracks and/or fractures within the first material.

Before the two materials are connected, the second material can already be completely formed into the second component, and the heating during connection can only be used to heat and melt it in a targeted manner at the connection surface, so that it enters the depression and undercut of the structure and/or around the structure flows around. Likewise, the second material can only be formed into the second component when it is connected to the first material. This can be done, for example, by casting or injection molding, in that the first material is placed in a corresponding mold or the injection molding material is sprayed onto the first material. In this case, the second material, which is used accordingly for casting or injection molding, is preferably completely heated.

Likewise, the connection of the first material and the second material can take place with sintering of fine-grained ceramic and/or metallic substances as the first material under increased pressure, with temperatures below the melting temperature of the respective first material being used, but the second material as a thermoplastic already in the connection area melts and flows accordingly in and/or around the structure.

The connection of the first material and the second material and thus the surrounding and/or filling of the structure is preferably carried out by thermal joining. In this case, the laser-structured first material is pressed in particular with the second material, which is locally heated, with the second material, in particular thermoplastic, penetrating into the structuring of the first material and adhering to its surface.

For thermal joining, the heat can be applied in particular by means of inductive heating and/or laser heating. In the case of inductive heating, the second material can be heated in a targeted manner and brought into the flowable state by using a coil through which high-frequency alternating current flows as an inductor, which generates an alternating magnetic field and thus induces eddy currents in the second material, for example in the pressing tool for thermal joining and/or is arranged directly in the first material or component. For laser heating, for example, an ultra short beam laser is used.

Using the method described above, a composite component comprising two different materials is produced with a firm connection taken, in which a predetermined breaking point or multiple predetermined breaking points are formed depending on the direction. It is particularly advantageous that the direction-dependent predetermined breaking point or the direction-dependent predetermined breaking points between the first material and the second material break or break without being heated when a directed force is applied. Consequently, the composite component can be designed in a targeted manner in such a way that the predetermined breaking points break only when the action is taken from a very specific direction and/or in the event of an intended, precisely defined hazard.

• 1 eine stark schematische Schnittdarstellung eines Ausschnittes eines Stahlbauteils mit Vertiefungen, und
• 2 eine stark schematische Schnittdarstellung eines Ausschnittes eines Verbundbauteils mit dem Stahlbauteil aus 1 und einem Polypropylen-Bauteil mit einer ersten Vertiefung.

The invention is explained in more detail below using an exemplary embodiment. Show it

• 1 a highly schematic sectional view of a section of a steel component with indentations, and
• 2 a highly schematic sectional view of a section of a composite component with the steel component 1 and a polypropylene component having a first cavity.

A composite component 101 has a steel component 103 and a polypropylene component 105 (see in 2 a section of the composite component 101 with a filled first depression 107).

The composite component 101 is manufactured with the following work steps:

In one surface of the steel component 103, an in 1 Not shown laser introduced the first recess 107, a second recess 109, a third recess 111 and a fourth recess 113 by laser cutting. The depressions 107, 109, 111 and 113 each have a depth of approximately 150 μm and a width of approximately 100 μm. In order to cut a left side wall 121 of the respective depression 107, 109, 111 and 113, the laser beam 119 is aligned at an angle of 50° to the horizontal orientation of the surface of the steel component 103, as a result of which a left undercut 125 is formed within the respective depression 107, 109, 111 and 113 arises. In order to cut into the respective right-hand side wall 123 of the respective depression 107, 109, 111 and 113, the laser beam 119 is aligned at an angle of 70° to the horizontal surface of the steel component 103.

In the case of the third depression 111 and the fourth depression 113, the cutting by means of the laser beam 119 is also carried out on the respective left-hand side wall 121 in such a way that the material of the steel component 103 is thrown up on the outer surface of the steel component 103 during the laser beam cutting, thereby creating a crater edge 117 as a additional structuring on the left side wall 121 is formed.

Subsequently, the steel component 103 with the recesses 107, 109, 111 and 113 introduced is pressed with a prefabricated polypropylene component 105 with thermal joining using a pressing tool, not shown, with the polypropylene component 105 being pressed in a targeted manner on its side due to induction heating in the pressing tool, not shown is heated and melts, which is aligned with the structured surface of the steel component 103 with the depressions 107, 109, 111 and 113. As a result, the heated and melted polypropylene material flows into the first depression 107, second depression 109, third depression 111 and fourth depression 113 and thus also fills the left undercut 125 in the respective depression 107, 109, 111 and 113.

At the same time, the molten polypropylene material surrounds the entire upper surface of the steel component 103, including the crater edges 117 of the third and fourth depressions 111, 113. Here, the prefabricated polypropylene component 105 is reshaped due to the melting and pressing by means of the pressing tool, not shown, and due to the penetration of the polypropylene melt into the depressions 107, 109, 111 and 113, a positive connection is achieved with the polypropylene adhering to the outer upper and inner surface of the steel component 103, so that both a positive and a material connection of the steel component 103 and the polypropylene Component 105 is present.

Due to the different angles of the laser beam 119 for forming the respective left side wall 121 and the right side wall 123 of the depressions 107, 109, 111 and 113, the respective left undercut 125 within the respective depression 107, 109, 111 and 113 has a larger left blocking dimension 127 as a corresponding right undercut 129 with a right locking dimension 131 in the steel member 103 (see Fig 2 ). As a result, the respective left undercut 125 can absorb a greater tensile force in a pulling direction 133 than the corresponding right undercut 129. Accordingly, a force which is parallel to the alignment of the respective right side wall 123 of the depressions 107, 109, 111 and 113 is directed upwards , a targeted, direction-dependent predetermined breaking point between the connected steel component 103 and the polypropylene component 105 of the composite component 101 can be effected.

Reference List

101

composite component

103

steel component

105

Polypropylene component

107

first deepening

109

second deepening

111

third deepening

113

fourth deepening

117

crater rim

119

laser beam

121

left side wall of the cavity

123

right side wall of the well

125

left undercut

127

left lock dimension

129

right undercut

131

right lock dimension

133

Direction of movement when blocked

Claims (10)

Method for manufacturing a composite component (101) and introducing a predetermined breaking point in the composite component, wherein the manufactured composite component has a first component (103) with a first material and a second component (105) with a second material, and the first material and the second Material have different material properties, with the following steps: - Introduction and/or application of a structure (107, 109, 111, 113) in and/or on the first material by means of a laser by acting in and/on the first material in such a way that a first undercut ( 125) is formed with a detent and a second side of the structure opposite the first side is free of an undercut or has a second undercut (129), the second undercut having a lesser detent than the first undercut, and - connecting the first material and the second material and surrounding and/or filling the structure with the second material under the action of heat, so that the manufactured composite component is present with a predetermined breaking point when a directed force acts in a direction deviating from the blocking of the first undercut. procedure after claim 1 , characterized in that before the connection, a second structure, a third structure, a fourth structure, a fifth structure and/or further structures is or are introduced into and/or onto the first material by means of the laser. procedure after claim 1 or 2 , characterized in that with the respective structure, a recess (107, 109, 111, 113) is introduced into the first material and/or an elevation (117) is applied to the first material. Method according to one of the preceding claims, characterized in that with a horizontal alignment of the first material the laser is at an angle in a range of 15° to 85°, in particular 25° to 70°, preferably 40° to 60° to the horizontal alignment of the first material is aligned when the respective structure is introduced and/or applied. Method according to one of the preceding claims, characterized in that a structure depth and/or height in a range from 50 µm to 500 µm, in particular 75 µm to 250 µm, preferably 100 µm to 200 µm, is introduced and/or applied by means of the laser will. Method according to one of the preceding claims, characterized in that a solid metal material and/or a ceramic material is or are used as the first material and a thermoplastic is or are used as the second material. Method according to one of the preceding claims, characterized in that the second material has already been preformed into the second component before the connection and/or is shaped into the second component during the connection. Method according to one of the preceding claims, characterized in that the joining of the first material and the second material and the surrounding and/or filling of the structure is carried out by casting, injection moulding, sintering and/or thermal joining. Method according to one of the preceding claims, characterized in that in the case of thermal joining, the heat is applied by means of inductive heating and/or laser heating. Composite component (101) comprising two different materials, characterized in that the composite component by a method according to one of Claims 1 until 9 is manufactured so that there is a direction-dependent predetermined breaking point in the composite component, in particular a direction-dependent predetermined breaking point which can be broken free of heating due to the action of a directed force.

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