DE102020205566A1 - Metal insert for use in plastic components - Google Patents

Abstract

A metal insert (110) for use in a plastic component (112) is proposed. The metal insert (110) has a first end face (116) and a second end face (118) each with a flange geometry (120). The flange geometries (120) of the first end face (116) and the second end face (118) are arranged plane-parallel to one another. The metal insert (110) has a cylindrical base body (122) which is arranged between the first end face (116) and the second end face (118). The flange geometries (120) have a diameter which is larger than the diameter of the base body (122). The base body (122) has a shaft (124) and a securing area (126). The securing area (126) has a lateral surface (128) with a plurality of polygonal toothing geometries (130). The polygonal toothing geometries (130) are arranged along a curve running parallel to an axis of rotation (132) of the base body (122).

Description

Technical area

The invention relates to a metal insert for use in a plastic component. The metal insert can be used in a plastic injection molding process, in particular for feeding and / or inserting into an injection molding tool for polymer materials. The invention also relates to a method for producing a plastic component. The devices and methods according to the invention can in particular be used in automobiles. In principle, other areas of application are also possible.

Technical background

Several metal inserts for plastic components are known from the prior art, for example in the form of threaded inserts, see for example DE 10 2013 217 448 A1 , DE 20 2014 100 008 U1 , DE 10 2009 051 037 A1 . Also known is a direct installation during an injection molding process itself, for example when it is directly inserted or fed into a polymer injection mold, as well as a subsequent introduction of the metal insert into an already manufactured component by applying force, with or without additional energy input in the form of heat.

Metal inserts for use in polymer materials usually have a geometry to secure against radial relative movement and an internal geometry. The internal geometry can be designed as a thread for fastening or as a support or guide bore to support axial or radial guide movements. A direct safeguard against an axial relative movement can be guaranteed by a force fit or a form fit, depending on the load.

The document DE 20 2010 017 804 U1 describes a threaded insert for overmolding, comprising a shank with collars defining two axially facing away heads of the insert, the shank being provided with an axially internally threaded section to form a thread and further being provided with means for blocking rotation of the Insert after encapsulation, and with means for blocking the insert axially in a translational direction after encapsulation, which are provided on the outside of the shaft. The shaft has at least one deformation zone with increased axial deformability between the axial section with internal thread and one of the two heads, which zone is designed to deform under a defined axial compression load acting on the heads without deformation of the axial section with internal thread to cause.

In addition, further threaded inserts are known from the prior art which have a safeguard against radial relative movement, see for example DE 198 56 611 A1 , DE 20 2009 005 298 U1 , US 2012/0189403 A1 , DE 100 13 091 A1 , DE 101 39 169 A1 , DE 10 2013 202 583 B3 , DE 10 2013 217 448 A1 , DE 10 2015 223 473 A1 , DE 20 2007 013 153 U1 , DE 2355 166 A1 , DE 29 17 934 A1 , US 2013017032 A1 .

With thread inserts of this type, the polymer material can flow freely around the thread insert due to manufacturing of the total height or plane parallelism that is not in accordance with tolerances. Here, the polymer material can get into the internal geometry. Free flowing polymer material can negatively affect the function of the entire assembly. Entry of excess polymer material into the internal geometry is a function-inhibiting defect. Furthermore, a wide variety of requirements for the force absorption of the connection are not achieved due to inadequate securing geometry against relative movement.

Object of the invention

It would therefore be desirable to provide a metal insert and a method for joining metal insert and polymer material which at least largely avoid the disadvantages of known devices and methods. In particular, a method for producing a plastic component with reduced complexity is to be made possible while at the same time increasing the functionality of the plastic component.

General description of the invention

This object is addressed by devices and methods with the features of the independent patent claims. Advantageous developments, which can be implemented individually or in any combination, are presented in the dependent claims.

In the following, the terms “have”, “have”, “comprise” or “include” or any grammatical deviations therefrom are used in a non-exclusive manner. Accordingly, these terms can relate both to situations in which, besides the features introduced by these terms, no further features are present, or to situations in which one or more further features are present. For example, the expression “A has B ”,“ A has B ”,“ A includes B ”or“ A includes B ”both refer to the situation in which, apart from B, no further element is present in A (ie to a situation in which A consists exclusively of B), as well as the situation in which, in addition to B, one or more further elements are present in A, for example element C, elements C and D or even further elements.

It is also pointed out that the terms “at least one” and “one or more” as well as grammatical modifications of these terms, if they are used in connection with one or more elements or features and are intended to express that the element or feature is provided once or several times can be used, as a rule, only once, for example when the feature or element is introduced for the first time. If the feature or element is subsequently mentioned again, the corresponding term “at least one” or “one or more” is generally no longer used, without restricting the possibility that the feature or element can be provided once or several times.

Furthermore, the terms “preferably”, “in particular”, “for example” or similar terms are used below in connection with optional features, without this limiting alternative embodiments. Features introduced by these terms are optional features, and it is not intended to use these features to restrict the scope of protection of the claims and in particular of the independent claims. Thus, as the person skilled in the art will recognize, the invention can also be carried out using other configurations. In a similar way, features which are introduced by “in an embodiment of the invention” or by “in an exemplary embodiment of the invention” are understood as optional features, without this being intended to limit alternative configurations or the scope of protection of the independent claims. Furthermore, by means of these introductory expressions, all possibilities of combining the features introduced in this way with other features, be it optional or non-optional features, remain untouched.

In a first aspect, a metal insert for use in a plastic component is proposed within the scope of the present invention.

The term “insert” as used here is a broad term which is to be given its usual and common meaning as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, refer in particular to a construction element in the form of a hollow cylinder, which enables a connection between two materials. The term “metal insert” as used here is a broad term to which its customary and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to an insert made of at least one metal. The metal insert can be produced from an element selected from the group consisting of: an unalloyed steel, a single-alloy steel, a multi-alloy steel, a non-ferrous (non-ferrous) metal. The metal insert can have at least one surface coating. As will be explained in detail below, the metal insert can be produced by cold forming. The metal insert can be designed as a threaded insert, threaded socket, insert, insert element, injection socket, press-in socket, rivet socket, press-in nut or rivet nut. The metal insert can have at least one internal thread, in particular for screw connections. A material can be screwed into the internal thread. An additional component or an assembly can be attached to the metal insert and / or to the plastic component via the internal thread.

To produce a plastic component, the metal insert can be at least partially encased with a polymer material in at least one plastic injection molding process. As used herein, the term "sheathing" is a broad term that has been given its ordinary and common meaning should as the skilled person understands them. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to an enclosure of the metal insert by polymer material, in particular in the form of a fixed connection between the two components. The term “at least partially encased”, as used here, is a broad term to which its customary and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to a complete sheathing, with configurations being possible in which only partial areas of the metal insert are sheathed by the polymer material. In particular, the distal ends of the metal insert remain uncovered and freely accessible from the outside.

The term “plastic component” as it is used here is a broad term to which its usual and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, refer in particular to a component which has at least one polymer material. Suitable polymer materials include common materials for plastic components, such as thermoplastics, thermosets, elastomers and fiber-reinforced composite materials. Materials that can be processed by means of a plastic injection molding process, extrusion and / or forming process, preferably by means of a plastic injection molding process, are particularly suitable. Such polymer materials can include, for example, acrylonitrile butadiene styrene (ABS); Polyamide (PA); Polyimide (PI); Polylactate (PLA); Cellulose acetate, cellulose acetate butyrate, proprionate, phthalate; Polymethyl methacrylate (PMMA) and copolymers thereof; Polymethacrylmethylimide (PMMI); Polysulfone (PSU); Polyvinyl acetate (PVAC); Polycarbonate (PC), polyglycolic acid (PGA), thermoplastic starch (TPS); Polycaprolactone (PCL), polyhydroxybutyric acid (PHB); Polyethylene terephthalate (PET); Polytetrafluoroethylene (PTFE); Polyolefins such as polypropylene (PP), polyethylene (PE), polystyrene (PS) and their copolymers; Polyether ketone (PEEK); Polyvinyl chloride (PVC); Rubbers such as ethylene-propylene rubber, natural rubber; Polyisobutylene (PIB); Polyvinyl butyral (PVB); Ethylene vinyl acetate; Silicones; Polyurethane (PUR); Epoxy resins; Vinyl ester resin; Melamine resin; Urea resin; Formaldehyde resins including urea, melamine, phenol, melamine / phenol-formaldehyde resin. Suitable fiber-reinforced composite materials can include glass fibers, carbon fibers, basalt fibers, ceramic fibers, quartz fibers, steel fibers and / or natural fibers such as flax, hemp, sisal or wood, reinforced thermoplastic, elastomeric and / or thermosetting materials, in particular selected from the polymer materials listed above will. Fiber-reinforced composite materials can preferably contain an addition of fibers of up to 60% by weight. A particularly suitable polymer material is polypropylene. The plastic component can be a plastic injection-molded component. The plastic component can be produced by at least one plastic injection molding process, extrusion and / or a forming process, preferably by a plastic injection molding process, in which the metal insert is coated with the polymer material.

The metal insert has a first end face and a second end face, each with a flange geometry. The flange geometries of the first and the second end face are arranged plane-parallel to one another. The metal insert has a cylindrical base body which is arranged between the first end face and the second end face. The flange geometries have a diameter which is larger than the diameter of the base body. The main body has a shaft and a securing area. The securing area has a lateral surface with a plurality of polygonal toothing geometries. The polygonal toothing geometries are arranged along a curve running parallel to an axis of rotation of the base body.

The term “end face”, as used here, is a broad term to which its customary and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to an upper or lower end of the metal insert. The metal insert can be a partially cylindrical body and the first and the second end face can be referred to as the base surface and the top surface. The designation “first end” can refer to the upper end and the designation “second end” can refer to the lower end of the metal insert. However, a reverse designation is also possible.

The term “flange geometry”, as used here, is a broad term to which its usual and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to a sealing connecting element. The flange geometry on the first end face can be designed as a flange running around the first end face. The flange geometry on the second end face can be designed as a flange running around the second end face. The flange geometries can in principle have any shape. The flange geometries can preferably be designed to be circular. The flange geometries on the end faces can have any diameter within a process-related relationship to the base body. The diameter of the respective flange geometry on one face can be defined separately. The two diameters of the flange geometries can be of different sizes independently of one another. The flange geometries have a diameter which is larger than the diameter of the base body. The flange geometries can have a larger diameter than the base body, so that they thus protrude beyond the base body. The flange geometries on the end faces can have identical or different diameters. The flange geometries can protrude beyond the main body of the metal insert. The flange geometries can each have a rim which protrudes beyond the base body. The flange geometries can be produced by at least one cold forming. the Flange geometries can enable forces to be absorbed in the axial direction. The force is absorbed in the radial or circumferential direction by the toothing.

A transition between the base body and at least one of the flange geometries can have a radius. The defined radius can provide a possibility for controlled deformation of the component.

The flange geometries of the first end face and the second end face are arranged plane-parallel to one another. The term “plane-parallel”, as it is used here, is a broad term to which its usual and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to a configuration of the flange geometries such that the flange geometries are arranged in two essentially parallel planes. In this context, “essentially parallel” can be understood to mean that the planes are completely parallel, with tolerances being conceivable. For example, a metal insert with a metric thread M4, M5, M6 can have a flatness tolerance of 0.050 mm. An allowed tolerance can depend on several factors. For example, an allowed tolerance can depend on which tolerance is required in order to fulfill a sealing function. The accuracy of an injection molding machine can also be incorporated here. For example, an allowed tolerance can depend on the tolerance that can be produced during extrusion, including the second flange geometry. This can depend on the exact geometry gradations and diameter-length ratios of the metal insert.

The flange geometries can be designed as plane-parallel sealing surfaces and / or flat sealing surfaces. The flange geometries can preferably be designed as plane-parallel sealing surfaces and flat sealing surfaces in order to fulfill a sealing function. Due to the small tolerance field of shape and position tolerances in the parallelism of the end faces to one another and the evenness of these, sealing against excess polymer material can be guaranteed. In particular, the plane-parallel design of the flange geometries on the end faces of the metal insert prevents the entry of polymer materials. Due to the low permissible manufacturing tolerance of shape and position, in particular parallelism and flatness of the flange geometries to one another, no additional complex compensation process in the injection molding process, such as high precision in tool manufacture and / or complex spring-loaded clamping assemblies, is required.

The flange geometries can ensure protection against relative axial movement. The term “axial relative movement”, as it is used here, is a broad term to which its usual and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to a movement of the metal insert along the axis of rotation of the metal insert with respect to the encasing polymer material. The flange geometries can act as securing geometries and ensure a firm fit in the polymer material with higher pull-out forces that can be achieved, i.e. forces acting in the axial direction. As a double flange, the flange geometries on the end faces can provide a safeguard against axial relative movement, in particular in the case of screwing, that is to say in the case of screwing.

The metal insert has a cylindrical base body which is arranged between the first end face and the second end face. The term “basic body” as it is used here is a broad one Term to which its ordinary and common meaning should be given, as understood by those skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to a three-dimensional body. The terms “cylinder” or “cylindrical”, as they are used here, are broad terms to which their customary and common meaning should be assigned, as understood by the person skilled in the art. The terms are not limited to any specific or customized meaning. The terms can, without limitation, relate in particular to a geometric body that is enclosed by two end faces and a lateral surface. The cylinder can be a circular cylinder. The base body can be a cylinder, in particular a circular cylinder or a hollow cylinder. The base body can be expanded by additional geometric bodies or its volume can be reduced in the form of cutouts. The flange geometries have a diameter which is larger than the diameter of the base body. For example, a ratio of the diameter of the base body and flange geometry with respect to the outer diameter can be in a range from 1: 1.5 to 1: 2. The base body can have any height. In particular, an overall length of the metal insert can be freely selected depending on the manufacturing process limitations.

The cylindrical base body of the metal insert according to the invention has a shaft and a securing area. The term “shaft” as used here is a broad term to which its customary and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, refer in particular to a section or area of the cylindrical base body which connects one of the flange geometries and the securing area to one another and / or provides a grip option. The shaft can be a region of the base body on which no toothing geometries are arranged. The main body can have a reduced shaft. “Reduced shaft” can be understood to mean that the base body has additional areas in addition to the shaft. Viewed from a lower end of the metal insert, the shaft is arranged below the securing area.

The term “security area” as used here is a broad term to which its usual and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to a section or region of the cylindrical base body of the metal insert which has toothing geometries. The securing area has a lateral surface with a plurality of polygonal toothing geometries, the polygonal toothing geometries being arranged along a curve running parallel to an axis of rotation of the base body.

The term “lateral surface”, as used here, is a broad term to which its customary and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to a surface of a body, in particular a rotationally symmetrical body. The lateral surface can be uniformly curved everywhere with a constant radius of curvature. The lateral surface can have locally different radii of curvature.

The term “tooth geometry”, as used here, is a broad term to which its customary and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to polygonal elements which are arranged on the lateral surface of the security area. The toothing geometry can be a projection which protrudes from the outer surface of the securing area. The toothing geometries can each be set up to protrude into the plastic component in the casing of the metal insert made of polymer material and to anchor the metal insert in the polymer material. The securing area has any number of toothing geometries. The securing area has a plurality of toothing geometries, in particular six, seven, eight, nine, ten, more than ten toothing geometries. For example, the securing area can have a plurality of circular area segments, each with at least one toothing geometry. The number of tooth geometries can be selected according to the requirements. The number of toothing geometries can have a direct influence on the formability or the required forming force and tool life. For example, six toothing geometries can be provided for metal inserts of size M4, M5 and M6. For larger diameters such as M8, M10, M12, 6 ± 2 tooth geometries can be conceivable, for example. The toothing geometries can be arranged at equal intervals around the lateral surface of the securing area.

The term “polygon” as it is used here is a broad term to which its usual and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, refer in particular to a two-dimensional or three-dimensional shape (then polyhedron). In particular, the term “polygon” can refer to any polygonal geometry with straight edges.

The polygonal toothing geometries are arranged along a curve running parallel to an axis of rotation of the base body. The term “curve” as used here is a broad term to which its usual and common meaning should be given, as understood by those skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to a profile of the toothing geometry. The tooth geometries can be trapezoidal. The term “trapezoidal”, as used here, is a broad term to which its customary and common meaning is to be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, refer in particular to the fact that the toothing geometries can have a trapezoidal profile along the lateral surface of the base body. The toothing geometries can each have at least one element selected from the group consisting of: wedges; Pink; three-dimensional geometries with a trapezoidal cross-section; three-dimensional geometries with a polygonal base; three-dimensional Geometries with a cycloidal base; three-dimensional geometries with an involute base surface extending to the cylindrical base body. The term “trapezoidal cross-section” as used here is a broad term to which its usual and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, refer in particular to the fact that the toothing geometries have a trapezoidal cross-section in a plane parallel to the flange geometries. The term “prong”, as used here, is a broad term to which its usual and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, refer in particular to the tip of a polygon. The term “wedge” as used here is a broad term which is to be given its usual and common meaning as understood by those skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to a body in which two side surfaces converge at an acute angle.

The toothing geometries can be set up as securing geometries against radial relative movements. The radial relative movement can be a movement perpendicular to the axis of rotation of the metal insert. The metal insert can have axially extending securing geometries against radial relative movement. The toothing geometries can have a surface for power transmission. The term “surface for power transmission”, as it is used here, is a broad term to which its usual and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, refer in particular to a surface that can be used for a force-locking connection between two components. A normal force on the surfaces to be connected can prevent their mutual displacement. For example, the inclined plane of the wedges can be used as a surface for power transmission. The securing geometries can have a sufficiently large projected area for the transmission of force to the polymer material in order to enable higher forces to be exerted than with known metal inserts.

The toothing geometries can be cold-formed along a curve on the lateral surface of the cylindrical securing area, running parallel to the axis of rotation. The toothing geometries can be produced by cold forming and / or extrusion. The term “extrusion”, as used here, is a broad term to which its usual and common meaning should be given, as understood by those skilled in the art. The term is not limited to any specific or adapted meaning. Of the The term can, without limitation, refer in particular to a forming process in which there is predominantly compressive stress on the workpiece to be formed. The compressive stress can take place, for example, by a press or a stamp.

The metal insert can comprise a bore, also referred to as internal geometry, for example an internal bore with a thread or a through bore. In particular for creating screw-on points, the metal insert can have an internal geometry, for example a fixed screw-on connection with an internal thread. The thread can be used for screw connections. The through hole can be used for supporting and / or sliding functions. The term “thread” as used here is a broad term to which its usual and common meaning should be assigned, as understood by those skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, refer in particular to a profiled notch which runs continuously in a helical manner in a cylindrical inner or outer wall. The thread can in particular be an internal thread, that is to say run in an inner wall, and accommodate a screw. The internal thread can be clockwise or counterclockwise. The thread can be a metric coarse thread according to the International Organization for Standardization (ISO), a metric ISO fine thread or an inch thread according to the Unified National Fine Thread Series (UNF) or the Unified Coarse Thread Series (UNC). The thread can be produced by thread forming, that is to say by deformation by means of a thread former. The thread can be cut. The inner bore can have a threaded bore with an inlet and outlet bevel. The hole can be designed as a fixed screw-on body with a through hole. The hole can be produced with a hole in the selected ISO tolerance for holes. The hole can be designed as an axial sliding function as well as a radial support function for a fit hole. The hole can be made with a hole in the selected ISO tolerance for fits. The term “through hole” as used here is a broad term to which its usual and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to a hole drilled through a component. The through hole can in particular be cylindrical. A bolt or a rivet, in principle also a screw, can be passed through the through hole, provided that their diameter is smaller than the diameter of the through hole. The through hole can be smooth. The bore can be stepped, in particular with regard to receiving a spring element. The through hole can be used for riveting. The bore can have a through bore with inlet and outlet slopes for guiding and / or supporting axial relative movement through the component. Screw connections, guide aids and support points can be created depending on the hole. The bore in combination with the flange geometry can provide a reinforcement of a screwing point or connection point. The flange geometries can prevent relaxation influences on the screw connection.

The metal insert can be characterized by a reduced shaft with plane-parallel flange geometries on the respective end faces and an axially extending securing geometry against radial relative movement. The hole can be an inner hole with a thread for fastening or as a through hole for support as well as for sliding functions.

For example, the metal insert can be designed as a threaded bushing, insert, threaded insert, insert element or injection bushing. The metal insert can have rotationally symmetrical upper and lower sides, each comprising a flange geometry. The securing area can be provided with six teeth evenly distributed around the circumference between the respective flange geometries. The metal insert can have a threaded hole with an inlet and outlet bevel.

In a further aspect of the present invention, a plastic component comprising the metal insert according to the invention is proposed. For definitions with regard to the plastic component, reference can be made to the definitions and configurations of the metal insert.

The plastic component can have at least one polymer material. Suitable polymer materials include common materials for plastic components, such as thermoplastics, thermosets, elastomers and fiber-reinforced composite materials. Materials that can be processed by means of a plastic injection molding process, extrusion and / or forming process, preferably by means of a plastic injection molding process, are particularly suitable. Such polymer materials can include, for example, acrylonitrile butadiene styrene (ABS); Polyamide (PA); Polyimide (PI); Polylactate (PLA); Cellulose acetate, cellulose acetate butyrate, propionate, phthalate; Polymethyl methacrylate (PMMA) and copolymers thereof; Polymethacrylmethylimide (PMMI); Polysulfone (PSU); Polyvinyl acetate (PVAC); Polycarbonate (PC), polyglycolic acid (PGA), thermoplastic starch (TPS); Polycaprolactone (PCL), polyhydroxybutyric acid (PHB); Polyethylene terephthalate (PET); Polytetrafluoroethylene (PTFE); Polyolefins such as polypropylene (PP), polyethylene (PE), polystyrene (PS) and their copolymers; Polyether ketone (PEEK); Polyvinyl chloride (PVC); Rubbers such as ethylene-propylene rubber, natural rubber; Polyisobutylene (PIB); Polyvinyl butyral (PVB); Ethylene vinyl acetate; Silicones; Polyurethane (PUR); Epoxy resins; Vinyl ester resin; Melamine resin; Urea resin; Formaldehyde resins including urea, melamine, phenol, melamine / phenol-formaldehyde resin. Suitable fiber-reinforced composite materials include glass fibers, carbon fibers, basalt fibers, ceramic fibers, quartz fibers, steel fibers and / or natural fibers such as flax, hemp, sisal, wood, reinforced thermoplastic, elastomeric and / or thermosetting materials, in particular selected from the polymer materials listed above will. Fiber-reinforced composite materials can preferably contain an addition of fibers of up to 60% by weight. A particularly suitable polymer material is polypropylene. The plastic component can be a plastic injection-molded component. The plastic component can be produced by at least one plastic injection molding process in which the metal insert is coated with the polymer material. The term “polymer material”, as used here, is a broad term to which its customary and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, refer in particular to chemical substances composed of long-chain macromolecules with predominantly organic repeating units, which can be used in particular to produce semi-finished products or molded parts. Polymer materials, also called plastics, can be produced synthetically with adjustable chemical properties such as elasticity or temperature resistance. Polymer materials such as polypropylene can be used, for example, in vehicle technology for the production of interior equipment, for example a car, for example for the dashboard, interior trim, for example in the car, center console, privacy screen, door trim, wall coverings, headliner covers, trunk covers, seat covers, general covers, in particular in Combination with other materials can be used. Other applications are also conceivable, for example for medical equipment, seats in aircraft, horticulture, agriculture, forestry, or civil engineering machines.

The metal insert can be embedded in the plastic component. As used herein, the term “embedded” is a broad term to which its customary and common meaning should be given as understood by those skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to an integration of the metal insert into the plastic component, in particular by sheathing the metal insert with polymer material.

In a further aspect of the present invention, a method for producing a plastic component is proposed. The process steps can be carried out in the order given. A different order is also possible in principle. Furthermore, one or more or all of the method steps can also be carried out repeatedly. Furthermore, two or more of the method steps can also be carried out completely or partially in a temporally overlapping manner or at the same time. In addition to the method steps mentioned, the method can also comprise further method steps.

1. a) Bereitstellen eines erfindungsgemäßen Metalleinsatzes;
2. b) Ummanteln des Metalleinsatzes mit mindestens einem Polymerwerkstoff in einem Spritzgusswerkzeug unter Verwendung eines Kunststoffspritzprozesses.

The procedure consists of the following steps:

1. a) providing a metal insert according to the invention;
2. b) Sheathing the metal insert with at least one polymer material in an injection molding tool using a plastic injection molding process.

The present invention relates both to the manufacturing process of the metal insert and to the further processing process into a plastic component. In method step a), a metal insert according to the invention is provided in one of its configurations. For definitions and configurations of the method, reference can be made to definitions and configurations of the metal insert and the plastic component.

Providing the metal insert can include producing the metal insert or using a finished metal insert. The provision of the metal insert can comprise at least one cold forming. By cutting a raw material to length, a semi-finished product can be produced, which is transported between the different forming stages by a transfer tool that serves the purpose. The forming tool of the respective forming stage can generate the required shape by means of a corresponding negative geometry. The number of forming stages can be designed according to the geometry and the state of the art. In particular, the provision of the metal insert includes cold forming at a low semi-finished product temperature to produce flange geometries on the end faces of the metal insert. The provision of the metal insert can include cold forming and / or extrusion for producing a toothing geometry on the outer surface of the securing area of the metal insert by means of at least one material flow at a low semi-finished product temperature.

The term “semi-finished product”, as used here, is a broad term to which its usual and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, refer in particular to a prefabricated raw material. Semi-finished products can include bar steel (wire section), for example. The term “semi-finished product temperature” as it is used here is a broad term to which its usual and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to the temperature to which the semifinished product is exposed, for example before and during further processing. The semi-finished product temperature can in particular be low or low. The further processing can include a forming process. The term “forming process” as it is used here is a broad term to which its usual and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, refer in particular to shaping manufacturing processes that bring about a targeted plastic change in shape. Forming processes can include, for example, rolling, forging, pressing or bending. Forming processes can be carried out with the use of supplied heat. The term “cold forming”, as used here, is a broad term to which its usual and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, refer in particular to the plastic deformation of metals below the recrystallization temperature.

1. i. Öffnen der Spritzgussform;
2. ii. Einführen des Metalleinsatzes;
3. iii. Fixieren des Metalleinsatzes;
4. iv. Schließen der Spritzgussform;
5. v. Einschießen des Polymerwerkstoffs;
6. vi. Öffnen der Spritzgussform;
7. vii. Auswerfen des Kunststoffbauteils.

In method step b), the provided metal insert is coated with at least one polymer material in an injection molding tool using a plastic injection molding process. Sheathing can include the following steps:

1. i. Opening the injection mold;
2. ii. Inserting the metal insert;
3. iii. Fixing the metal insert;
4. iv. Closing the injection mold;
5. v. Shooting in the polymer material;
6. vi. Opening the injection mold;
7. vii. Eject the plastic component.

The term “injection molding tool” as used here is a broad term to which its customary and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, relate in particular to tools for producing cast parts, in particular those made of plastic. The injection molding tool can comprise an injection mold which defines the shape of the cast part. The injection mold can for example be divided into two halves, between which the negative contour of the cast part can be designed as a cavity. When the injection molding tool is opened, the two halves can be moved apart, for example. The injection molding tool can comprise an expedient handling or auxiliary means for feeding or fixing the metal insert. When the injection molding tool is closed, for example two halves of the injection mold can be moved together. The injection molding tool can have a nozzle with connections for the injection of the polymer material.

The term “plastic injection molding process”, as it is used here, is a broad term to which its usual and common meaning should be assigned, as understood by the person skilled in the art. The term is not limited to any specific or adapted meaning. The term can, without limitation, refer in particular to an original molding process in which a solid body with a geometrically defined shape is produced from an initially shapeless material, in particular plastic, for example in the form of powder or granules. In the plastic injection process, the polymer material can be liquefied and injected under pressure into the injection mold via a nozzle of the injection molding tool. Blowing agents can be used to enable foaming of the polymer material. After injection into the injection mold, processes for further shaping the plastic component, such as blowing or stretching processes, can be added. The metal insert inserted and fixed in the injection mold can be encapsulated by the polymer material so that a plastic component can be produced and ejected from the injection mold after the injection mold has been reopened. The sealing flange geometries on the end faces of the metal insert can hold back the polymer material and thus spatially restrict its distribution. The injected metal insert can serve as a connection point and absorb the forces that the plastic alone could not withstand. After inserting and / or feeding the metal insert into a plastic injection molding tool, no additional process is necessary to create a connection point. Furthermore, a complex spring-loaded clamping assembly is not necessary during the plastic injection molding process.

The metal insert according to the invention and the method according to the invention have numerous advantages over known devices and methods. The toothing geometry in the securing area of the metal insert ensures radial securing of the metal insert in a plastic component. Axial securing can be achieved by using the metal insert by using plane-parallel flange geometries. These can be flush with the plastic on both sides. Said flange geometries can also seal the inner geometry of the metal insert against polymer material during the production of the plastic component. In doing so, they prevent the polymer material from penetrating the internal geometry during the plastic injection molding process, which would be a function-inhibiting defect, especially in the case of threaded inserts with internal threads. The method according to the invention also manages without compensation processes for adapting, for example, the height of the metal insert to an injection molding tool and can thus be kept as simple as possible.

• Ausführungsform 1: Metalleinsatz zur Verwendung in einem Kunststoffbauteil, wobei der Metalleinsatz eine erste Stirnseite und eine zweite Stirnseite mit jeweils einer Flanschgeometrie aufweist, wobei die Flanschgeometrien der ersten Stirnseite und der zweiten Stirnseite planparallel zueinander angeordnet sind, wobei der Metalleinsatz einen zylindrischen Grundkörper aufweist, welcher zwischen der ersten Stirnseite und der zweiten Stirnseite angeordnet ist, wobei die Flanschgeometrien einen Durchmesser aufweisen, welcher größer ist als der Durchmesser des Grundkörpers, wobei der Grundkörper einen Schaft und Sicherungsbereich aufweist, wobei der Sicherungsbereich eine Mantelfläche mit einer Mehrzahl von polygonen Verzahnungsgeometrien aufweist, wobei die polygonen Verzahnungsgeometrien entlang einer, parallel zu einer Rotationsachse des Grundkörpers verlaufenden, Kurve angeordnet sind.
• Ausführungsform 2: Metalleinsatz nach der vorhergehenden Ausführungsform, wobei ein Übergang zwischen Grundkörper und mindestens einer der Flanschgeometrien einen Radius aufweist.
• Ausführungsform 3: Metalleinsatz nach der vorhergehenden Ausführungsform, wobei die Flanschgeometrien kreisförmig mit identischem oder verschiedenem Durchmesser sind.
• Ausführungsform 4: Metalleinsatz nach einer der vorhergehenden Ausführungsformen, wobei der Metalleinsatz eine Innenbohrung mit einem Gewinde umfasst.
• Ausführungsform 5: Metalleinsatz nach einer der vorhergehenden Ausführungsformen, wobei der Metalleinsatz eine Durchgangsbohrung umfasst.
• Ausführungsform 6: Metalleinsatz nach einer der vorhergehenden Ausführungsformen, wobei die Verzahnungsgeometrien trapezförmig verlaufen.
• Ausführungsform 7: Metalleinsatz nach einer der vorhergehenden Ausführungsformen, wobei die Verzahnungsgeometrien jeweils mindestens ein Element aufweisen ausgewählt aus der Gruppe bestehend aus: Keilen; Zacken; dreidimensionalen Geometrien mit trapezförmigem Querschnitt; dreidimensionale Geometrien mit polygoner Grundfläche; dreidimensionale Geometrien mit zykloider Grundfläche; dreidimensionale Geometrien mit evolvent zum zylindrischen Grundkörper verlaufender Grundfläche.
• Ausführungsform 8: Metalleinsatz nach einer der vorhergehenden Ausführungsformen, wobei die Verzahnungsgeometrien in gleichen Abständen um die Mantelfläche des Sicherungsbereichs angeordnet sind.
• Ausführungsform 9: Metalleinsatz nach einer der vorhergehenden Ausführungsformen, wobei die Verzahnungsgeometrien eine Fläche zur Kraftübertragung aufweisen.
• Ausführungsform 10: Metalleinsatz nach einer der vorhergehenden Ausführungsformen, wobei die Flanschgeometrien durch mindestens eine Kaltumformung hergestellt sind. Ausführungsform 11: Metalleinsatz nach einer der vorhergehenden Ausführungsformen, wobei die Verzahnungsgeometrien durch eine Kaltumformung und/oder ein Fließpressen hergestellt sind.
• Ausführungsform 12: Kunststoffbauteil umfassend mindestens einen Metalleinsatz nach einem der vorhergehenden Ansprüche, wobei der Metalleinsatz in dem Kunststoffbauteil eingebettet ist.
• Ausführungsform 13: Verfahren zur Herstellung eines Kunststoffbauteils nach der vorhergehenden Ausführungsform, wobei das Verfahren die folgenden Schritte umfasst:
  1. a) Bereitstellen eines Metalleinsatzes nach einem der vorhergehenden, einen Metalleinsatz betreffenden, Ansprüche;
  2. b) Ummanteln des Metalleinsatzes mit mindestens einem Polymerwerkstoff in einem Spritzgusswerkzeug unter Verwendung eines Kunststoffspritzprozesses.
• Ausführungsform 14: Verfahren nach der vorhergehenden Ausführungsform, wobei das Ummanteln die folgenden Schritte umfasst:
  1. i. Öffnen der Spritzgussform;
  2. ii. Einführen des Metalleinsatzes;
  3. iii. Fixieren des Metalleinsatzes;
  4. iv. Schließen der Spritzgussform;
  5. v. Einschießen des Polymerwerkstoffs;
  6. vi. Öffnen der Spritzgussform;
  7. vii. Auswerfen des Kunststoffbauteils.
• Ausführungsform 15: Verfahren nach einer der vorhergehenden, ein Verfahren betreffenden, Ausführungsformen, wobei das Bereitstellen des Metalleinsatzes eine Kaltumformung bei geringer Halbzeugtemperatur zur Herstellung von Flanschgeometrien an den Stirnseiten des Metalleinsatzes umfasst.
• Ausführungsform 16: Verfahren nach einer der vorhergehenden, ein Verfahren betreffenden Ausführungsformen, wobei das Bereitstellen des Metalleinsatzes eine Kaltumformung und/oder ein Fließpressen zur Herstellung einer Verzahnungsgeometrie an der Mantelfläche eines Sicherungsbereichs des Metalleinsatzes durch mindestens einen Materialfluss bei niedriger Halbzeugtemperatur umfasst.

In summary, without restricting further possible configurations, the following embodiments are proposed:

• Embodiment 1: Metal insert for use in a plastic component, the metal insert having a first end face and a second end face each with a flange geometry, the flange geometries of the first end face and the second end face being arranged plane-parallel to one another, the metal insert having a cylindrical base body which is arranged between the first end face and the second end face, the flange geometries having a diameter which is greater than the diameter of the base body, the base body having a shaft and securing area, the securing area having a lateral surface with a plurality of polygonal toothing geometries, wherein the polygonal gear geometries along one, parallel to an axis of rotation of the base body extending, curve are arranged.
• Embodiment 2: Metal insert according to the preceding embodiment, a transition between the base body and at least one of the flange geometries having a radius.
• Embodiment 3: Metal insert according to the preceding embodiment, the flange geometries being circular with identical or different diameters.
• Embodiment 4: Metal insert according to one of the preceding embodiments, wherein the metal insert comprises an inner bore with a thread.
• Embodiment 5: Metal insert according to one of the preceding embodiments, wherein the metal insert comprises a through-hole.
• Embodiment 6: Metal insert according to one of the preceding embodiments, the toothing geometries running trapezoidally.
• Embodiment 7: Metal insert according to one of the preceding embodiments, the toothing geometries each having at least one element selected from the group consisting of: wedges; Pink; three-dimensional geometries with a trapezoidal cross-section; three-dimensional geometries with a polygonal base; three-dimensional geometries with a cycloid base; three-dimensional geometries with an involute base surface extending to the cylindrical base body.
• Embodiment 8: Metal insert according to one of the preceding embodiments, the toothing geometries being arranged at equal intervals around the outer surface of the securing area.
• Embodiment 9: Metal insert according to one of the preceding embodiments, the toothing geometries having a surface for power transmission.
• Embodiment 10: Metal insert according to one of the preceding embodiments, the flange geometries being produced by at least one cold forming. Embodiment 11: Metal insert according to one of the preceding embodiments, the toothing geometries being produced by cold forming and / or extrusion.
• Embodiment 12: Plastic component comprising at least one metal insert according to one of the preceding claims, wherein the metal insert is embedded in the plastic component.
• Embodiment 13: A method for producing a plastic component according to the preceding embodiment, the method comprising the following steps:
  1. a) providing a metal insert according to one of the preceding claims relating to a metal insert;
  2. b) Sheathing the metal insert with at least one polymer material in an injection molding tool using a plastic injection molding process.
• Embodiment 14: The method according to the preceding embodiment, wherein the sheathing comprises the following steps:
  1. i. Opening the injection mold;
  2. ii. Inserting the metal insert;
  3. iii. Fixing the metal insert;
  4. iv. Closing the injection mold;
  5. v. Shooting in the polymer material;
  6. vi. Opening the injection mold;
  7. vii. Eject the plastic component.
• Embodiment 15: Method according to one of the preceding embodiments relating to a method, wherein the provision of the metal insert comprises cold forming at a low semi-finished product temperature to produce flange geometries on the end faces of the metal insert.
• Embodiment 16: Method according to one of the preceding embodiments relating to a method, wherein the provision of the metal insert comprises cold forming and / or extrusion to produce a toothing geometry on the outer surface of a securing area of the metal insert by at least one material flow at a low semi-finished product temperature.

Figure list

Further details and features emerge from the following description of exemplary embodiments, in particular in conjunction with the subclaims. The respective features can be implemented individually or in combination with one another. The invention is not restricted to the exemplary embodiments. The exemplary embodiments are shown schematically in the figures. The same reference numbers in the individual figures designate elements that are the same or functionally the same or correspond to one another with regard to their functions.

• 1 eine Ausführungsform eines erfindungsgemäßen Metalleinsatzes im Halbschnitt;
• 2 eine Ausführungsform eines erfindungsgemäßen Kunststoffbauteils; und
• 3 ein Flussdiagramm eines Ausführungsbeispiels des erfindungsgemäßen Verfahrens.

Show in detail:

• 1 an embodiment of a metal insert according to the invention in half section;
• 2 an embodiment of a plastic component according to the invention; and
• 3 a flowchart of an embodiment of the method according to the invention.

Description of the exemplary embodiments

1 shows an embodiment of a metal insert according to the invention 110 for use in a plastic component 112 in half cut. A metal insert 110 can comprise a construction element in the form of a hollow cylinder, which enables a connection between two materials. The metal insert 110 may comprise a metal insert. The metal insert 110 can be made from an element selected from the group consisting of: an unalloyed steel, a single alloy steel, a multi-alloy steel, a non-ferrous (non-ferrous) metal. The metal insert 110 can have at least one surface coating. The metal insert 110 can be produced in a cold forming process. The metal insert 110 can be designed as a threaded insert, threaded socket, insert, insert element, injection socket, press-in socket, rivet socket, press-in nut or rivet nut. The metal insert 110 can have at least one internal thread, in particular for screw connections. A material can be screwed into the internal thread. An additional component or assembly can be attached to the metal insert via the internal thread 110 and / or attached to the plastic component.

The metal insert 110 has a first end face 116 and a second face 118 each with a flange geometry 120 on. The flange geometries 120 the first face 116 and the second face 118 are arranged plane-parallel to one another. The metal insert 110 has a cylindrical body 122 on, which is between the first face 116 and the second face 118 is arranged. The flange geometries 120 have a diameter which is larger than the diameter of the base body 122 . The main body has a shaft 124 and a backup area 126 on. The security area 126 has a lateral surface 128 with a plurality of polygonal toothing geometries 130 on. The polygonal gear geometries 130 are along, parallel to, an axis of rotation 132 of the main body 122 trending, curve arranged.

For example, the first end face 116 an upper end of the metal insert 110 be. For example, the second end face 118 a lower end of the metal insert 110 be. The metal insert 110 can be a partially cylindrical body. The first face 116 can be a top surface of the cylindrical metal insert. The second face 118 can be a base of the cylindrical metal insert.

The flange geometry 120 can be and / or comprise a sealing connecting element. The flange geometry 120 on the first face 116 can be used as the first face 116 be designed circumferential flange. The flange geometry 120 on the second face 118 can be used as a second end face 118 be designed circumferential flange. The flange geometries 120 can basically have any shape. The flange geometries can preferably 120 be designed circular. The flange geometries 120 on the front sides 134 can, within a process-related relationship to the base body 122 , have any diameter. The diameter of the respective flange geometry 120 on one end face can be defined separately. The flange geometries 120 on the front sides 134 can have identical or different diameters. The flange geometries 120 can over the base body 122 of the metal insert 110 protrude. The flange geometries 120 can each have a brim that extends over the base body 122 protrudes. The two diameters of the flange geometries 120 can be of different sizes independently of one another. The flange geometries 120 have a diameter which is larger than the diameter of the base body 122 . The flange geometries 120 can have a larger diameter than the base body 122 have, so that they are thus over the base body 122 protrude.

A transition 136 between base body 122 and at least one of the flange geometries 120 can have a radius as in 1 on the flange geometry 120 the second face 118 shown. The defined radius can provide a possibility for controlled deformation of the component. For example, the transition 137 between flange geometry 120 and base body 122 on the first face 116 , first one perpendicular to the flange geometry 120 running section 138 , followed by a sloping section 140 include.

The flange geometries 120 can be produced by at least one cold forming.

The flange geometries 120 the first face 116 and the second face 118 are arranged plane-parallel to one another. The flange geometries 120 can be arranged in two substantially parallel planes, tolerances being possible. For example, with a Metal insert 110 with metric threads M4, M5, M6 a flatness tolerance of 0.050 mm. An allowed tolerance can depend on several factors. For example, an allowed tolerance can depend on which tolerance is required in order to fulfill a sealing function. The accuracy of an injection molding machine can also be incorporated here. For example, an allowed tolerance can depend on the tolerance that can be produced during extrusion, including the second flange geometry. This can be due to the exact geometrical gradations and diameter-length ratios of the metal insert 110 depend.

The flange geometries 120 can be designed as plane-parallel sealing surfaces and / or flat sealing surfaces. The flange geometries 120 can preferably be designed as plane-parallel sealing surfaces and flat sealing surfaces in order to fulfill a sealing function. Due to the small tolerance field of form and position tolerances in parallelism of the front sides 134 to each other and the evenness of these, can seal against excess polymer material 114 guaranteed. In particular, the plane-parallel design of the flange geometries 120 on the front sides 134 of the metal insert 110 an entry of polymer materials 114 be prevented. Due to the low permissible manufacturing tolerance of shape and position, in particular parallelism and evenness of the flange geometries 120 to each other, no additional complex compensation process in the injection molding process, such as high precision in tool manufacture and / or complex spring-loaded clamping assemblies, is required.

The flange geometries 120 can ensure a safeguard against an axial relative movement. The axial relative movement can, in particular, be a movement of the metal insert 110 along the axis of rotation 132 of the metal insert 110 in relation to the encasing polymer material 114 include. The flange geometries 120 can act as securing geometries and a firm fit in the polymer material 114 with higher pull-out forces that can be achieved, i.e. forces acting in the axial direction. The flange geometries 120 can, as a double flange, provide a safeguard against an axial relative movement, in particular in the case of screwing, that is to say in the case of screwing.

The metal insert 110 has a cylindrical body 122 on, which is between the first face 116 and the second face 118 is arranged. The cylindrical body 122 can comprise a geometric body as a cylinder, which is formed by two end faces 134 and a lateral surface 128 is included. The cylinder can be a circular cylinder. The basic body 122 can be a cylinder, in particular a circular cylinder or a hollow cylinder. The basic body 122 can be expanded by additional geometric bodies or reduced in the form of recesses in its volume. The flange geometries 120 have a diameter which is larger than the diameter of the base body 122 . For example, a ratio of the diameter of the base body 122 and flange geometry 120 with respect to the outer diameter are in a range from 1: 1.5 to 1: 2. The basic body 122 can be of any height. In particular, a total length of the metal insert 110 can be freely selected depending on the manufacturing process limitations.

The cylindrical body 122 of the metal insert according to the invention 110 has a shaft 124 and a backup area 126 on. The shaft 124 can comprise a section or region of the cylindrical base body which has one of the flange geometries 120 and the security area 126 connects with each other and / or provides a grip. The shaft 124 can be an area of the base body 122 on which no gear geometries 130 are arranged. The basic body 122 can have a reduced stem 124 exhibit. The basic body 122 can in addition to the shank 124 have further areas. From the bottom of the metal insert 110 considered, the shaft is arranged below the securing area.

The security area 126 can be a section or area of the cylindrical base body 122 of the metal insert 110 include what gear geometries 130 having. The security area 126 has a lateral surface 128 with a plurality of polygonal toothing geometries 130 on, with the polygonal gear geometries 130 along one, parallel to an axis of rotation 132 of the main body 122 running, curve are arranged.

The outer surface 128 can be or comprise a surface of a body, in particular a rotationally symmetrical body. The outer surface 128 can be uniformly curved everywhere with constant radius of curvature. The outer surface 128 can have locally different radii of curvature. The gear geometry 130 may include polygonal elements on the lateral surface 128 of the security area 126 are arranged. The gear geometry 130 can be a projection, which from the lateral surface 128 of the security area 126 protrudes. The gear geometries 130 can each be set up in the plastic component 112 into the jacket of the metal insert 110 made of polymer material 114 protrude into it and the metal insert 110 in the polymer material 114 to anchor. The security area 126 has any number of Gear geometries 130 on. The security area 126 has a plurality of toothing geometries 130 on, in particular six, seven, eight, nine, ten, more than ten tooth geometries 130 . For example, the security area 126 have a plurality of circular surface segments, each with at least one tooth geometry 130 . The number of gear geometries 130 can be selected according to requirements. The number of gear geometries 130 can have a direct influence on the formability or the required forming force and tool life. For example, six toothing geometries can be used 130 for metal inserts 110 sizes M4, M5 and M6 can be provided. For larger diameters such as M8, M10, M12, 6 ± 2 tooth geometries can be used, for example 130 be conceivable. The gear geometries 130 can be spaced equally around the outer surface 128 of the security area 126 be arranged.

The polygonal gear geometries 130 can include two-dimensional (polygon) or three-dimensional (polyhedron) shapes, in particular with any polygonal geometry with straight edges. The polygonal gear geometries 130 are along, parallel to, an axis of rotation 132 of the main body 122 trending, curve arranged. The curve can be a profile of the gear geometry 130 include. The gear geometries 130 can be trapezoidal. Trapezoidal toothing geometries 130 can have a trapezoidal profile along the outer surface 128 of the main body 122 exhibit. The gear geometries 130 each may have at least one element selected from the group consisting of: wedges; Pink; three-dimensional geometries with a trapezoidal cross-section; three-dimensional geometries with a polygonal base; three-dimensional geometries with a cycloid base; three-dimensional geometries with an involute base surface extending to the cylindrical base body. Gear geometries 130 with a trapezoidal cross-section can be used in one of the flange geometries 120 parallel plane have a trapezoidal cross-section. Spikes can comprise tips of polygons. Wedges can include bodies with two side surfaces converging at an acute angle.

The gear geometries 130 can be set up as securing geometries against radial relative movements. The radial relative movement can be a movement perpendicular to the axis of rotation 132 of the metal insert 110 be. The metal insert 110 can have axially extending securing geometries against radial relative movement. The gear geometries 130 can have a surface for power transmission. The surface for power transmission can comprise a surface which can be used for a force-fit connection between two components. A normal force on the surfaces to be connected can prevent their mutual displacement. For example, the inclined plane of the wedges can be used as a surface for power transmission. The securing geometries can have a sufficiently large projected area for power transmission to the polymer material 114 have to have higher force than with known metal inserts 110 to enable.

The gear geometries 130 can along a curve on the lateral surface 128 of the cylindrical fuse area 126 , parallel to the axis of rotation 132 running cold-formed. The gear geometries 130 can be produced by cold forming and / or extrusion. The extrusion can include a forming process in which there is predominantly compressive stress on the workpiece to be formed. The compressive stress can take place, for example, by a press or a stamp.

The metal insert 110 can be a hole 142 , also known as internal geometry, with a thread or a through hole 144 include. In particular, the drilling can be used to create screw-on points 142 have an internal geometry, for example a fixed screw connection with an internal thread. The thread can be used for screw connections. The through hole 144 can be used for support and / or sliding functions. The thread can be a profiled notch which runs continuously helically in a cylindrical inner or outer wall. The thread can in particular be an internal thread, that is to say run in an inner wall, and accommodate a screw. The internal thread can be clockwise or counterclockwise. The thread can be a metric coarse thread according to the International Organization for Standardization (ISO), a metric ISO fine thread or an inch thread according to the Unified National Fine Thread Series (UNF) or the Unified Coarse Thread Series (UNC). The thread can be produced by thread forming, that is to say by deformation by means of a thread former. The thread can be cut. The hole 142 can have a threaded hole with an inlet and outlet slope. The hole 142 can be used as a fixed screw-on body with a through hole 144 are executed. The hole 142 can be produced with a hole in the selected ISO tolerance for holes. The hole 142 can be carried out as an axial sliding function as well as a radial support function for fit bores. The hole 142 can be produced with a hole in the selected ISO tolerance for fits. By the through hole 144 a bolt or a rivet, in principle also a screw, can be passed through, provided that their diameter is smaller than the diameter of the through hole 144 . The through hole can be smooth. The hole 142 can be stepped, in particular with regard to receiving a spring element. The through hole 144 can be used for riveting. The hole 142 can have a through hole 144 with inlet and outlet slope 146 have for guiding and / or supporting axial relative movement through the component. Screw connections, guide aids and support points can depend on the hole 142 be generated. The hole 142 in combination with the flange geometry 120 can provide a reinforcement of a screwing point or connection point. The flange geometries 120 can prevent relaxation influences on the screw connection.

The metal insert 110 can through a reduced shaft 124 with plane-parallel flange geometries 120 on the respective end faces 134 and axially extending securing geometry to be characterized against radial relative movement. The hole 142 can be threaded for attachment or as a through hole 144 for supporting as well as for sliding functions.

2 shows a schematic drawing of the plastic component according to the invention 112 comprising the metal insert according to the invention 110 . The metal insert 110 can be used to manufacture a plastic component 112 with a polymer material 114 are at least partially encased in at least one plastic injection molding process. Suitable polymer materials 114 include common materials for plastic components such as thermoplastics, thermosets, elastomers and fiber-reinforced composites. Materials that can be processed by means of a plastic injection molding process, extrusion and / or forming process, preferably by means of a plastic injection molding process, are particularly suitable. Such polymer materials can include, for example, acrylonitrile butadiene styrene (ABS); Polyamide (PA); Polyimide (PI); Polylactate (PLA); Cellulose acetate, cellulose acetate butyrate, propionate, phthalate; Polymethyl methacrylate (PMMA) and copolymers thereof; Polymethacrylmethylimide (PMMI); Polysulfone (PSU); Polyvinyl acetate (PVAC); Polycarbonate (PC), polyglycolic acid (PGA), thermoplastic starch (TPS); Polycaprolactone (PCL), polyhydroxybutyric acid (PHB); Polyethylene terephthalate (PET); Polytetrafluoroethylene (PTFE); Polyolefins such as polypropylene (PP), polyethylene (PE), polystyrene (PS) and their copolymers; Polyether ketone (PEEK); Polyvinyl chloride (PVC); Rubbers such as ethylene-propylene rubber, natural rubber; Polyisobutylene (PIB); Polyvinyl butyral (PVB); Ethylene vinyl acetate; Silicones; Polyurethane (PUR); Epoxy resins; Vinyl ester resin; Melamine resin; Urea resin; Formaldehyde resins including urea, melamine, phenol, melamine / phenol-formaldehyde resin. Suitable fiber-reinforced composite materials include glass fibers, carbon fibers, basalt fibers, ceramic fibers, quartz fibers, steel fibers and / or natural fibers such as flax, hemp, sisal, wood, reinforced thermoplastic, elastomeric and / or thermosetting materials, in particular selected from the polymer materials listed above will. Fiber-reinforced composite materials can preferably contain an addition of fibers of up to 60% by weight. A particularly suitable polymer material 114 is polypropylene. The sheathing can in particular enclose the metal insert 110 through polymer material 114 , in particular in the form of a permanent connection between the two components. Configurations are possible in which only partial areas of the metal insert are possible 110 from the polymer material 114 be sheathed. In particular, distal ends remain 148 of the metal insert 110 uncovered and freely accessible from the outside.

The metal insert 110 can in the plastic component 112 be embedded. By embedding the metal insert 110 in the plastic component 112 , in particular by sheathing the metal insert 110 with polymer material 114 be integrated. In the in 2 The schematic cross section shown surrounds the polymer material 114 the metal insert 110 laterally such that a total of a rectangular cross-section of the plastic component 112 comes about, which in practice can take a wide variety of forms.

3 shows a flow chart of an exemplary embodiment of the method according to the invention for producing a plastic component 112 . Method step a), characterized by the reference number 150 , and method step b), characterized by the reference number 152 , can be carried out in the order given. Furthermore, one or more or all of the method steps, in particular substeps of the method, can also be carried out repeatedly. Furthermore, two or more of the method steps can also be carried out completely or partially in a temporally overlapping manner or at the same time. In addition to the method steps mentioned, the method can also comprise further method steps.

1. a) Bereitstellen eines erfindungsgemäßen Metalleinsatzes 110;
2. b) Ummanteln des Metalleinsatzes 110 mit mindestens einem Polymerwerkstoff 114 in einem Spritzgusswerkzeug unter Verwendung eines Kunststoffspritzprozesses.

The procedure described in 3 , includes the following steps:

1. a) Providing a metal insert according to the invention 110 ;
2. b) Covering the metal insert 110 with at least one polymer material 114 in an injection mold using a plastic injection process.

The present invention relates to both the manufacturing process of the metal insert 110 , as well as the further processing into a plastic component.

In process step a) 150, a metal insert according to the invention is used 110 provided in one of its configurations. The provision of the metal insert 110 can produce the metal insert or use a finished metal insert 110 include. The provision of the metal insert 110 comprises at least one cold forming. By cutting a raw material to length, a semi-finished product can be produced, which is transported between the different forming stages by a transfer tool that serves the purpose. The forming tool of the respective forming stage can generate the required shape by means of a corresponding negative geometry. The number of forming stages can be designed according to the geometry and the state of the art. In particular, the provision of the metal insert comprises 110 a cold forming at a low temperature of the semi-finished product for the production of flange geometries 120 on the front sides 134 of the metal insert 110 . The provision of the metal insert 110 can be cold forming and / or extrusion to produce a gear geometry 130 on the outer surface 128 of the security area 126 of the metal insert 110 by at least one material flow at a low semi-finished product temperature.

Semi-finished product can comprise a prefabricated raw material. Semi-finished products can include bar steel (wire section), for example. The semi-finished product temperature can be the temperature to which semi-finished products are exposed, for example before and during further processing. The semi-finished product temperature can in particular be low or low. The further processing can include a forming process. The shaping process can include shaping manufacturing processes that bring about a targeted plastic change in shape.

Forming processes can include, for example, rolling, forging, pressing or bending. Forming processes can be carried out with the use of supplied heat. Cold forming can include the plastic forming of metals below the recrystallization temperature.

1. i. Öffnen der Spritzgussform;
2. ii. Einführen des Metalleinsatzes 110;
3. iii. Fixieren des Metalleinsatzes 110;
4. iv. Schließen der Spritzgussform;
5. v. Einschießen des Polymerwerkstoffs 114;
6. vi. Öffnen der Spritzgussform;
7. vii. Auswerfen des Kunststoffbauteils 112.

In method step b) 152, the provided metal insert 110 with at least one polymer material 114 encased in an injection mold using a plastic injection process. Sheathing can include the following steps:

1. i. Opening the injection mold;
2. ii. Insert the metal insert 110 ;
3. iii. Fixing the metal insert 110 ;
4. iv. Closing the injection mold;
5. v. Shooting in the polymer material 114 ;
6. vi. Opening the injection mold;
7. vii. Eject the plastic component 112 .

The injection molding tool can comprise tools for producing cast parts, in particular those made of plastic. The injection molding tool can comprise an injection mold which defines the shape of the cast part. The injection mold can for example be divided into two halves, between which the negative contour of the cast part can be designed as a cavity. When the injection molding tool is opened, the two halves can be moved apart, for example. The injection molding tool can be an expedient handling or auxiliary means for feeding or fixing the metal insert 110 include. When the injection molding tool is closed, for example two halves of the injection mold can be moved together. The injection molding tool can have a nozzle with connections for the injection of the polymer material 114 exhibit.

The plastic injection molding process can include a primary molding process in which a solid body with a geometrically defined shape is produced from an initially shapeless material, in particular plastic. In the plastic injection process, the polymer material 114 are liquefied and injected under pressure into the injection mold via a nozzle of the injection molding tool. The metal insert inserted and fixed in the injection mold 110 can from the polymer material 114 are overmolded, so that a plastic component 112 generated and can be ejected from the injection mold after reopening the injection mold. The sealing flange geometries 120 on the front sides 134 of the metal insert 110 the polymer material 114 hold back and thus restrict its distribution spatially. The injected metal insert 110 can serve as a connection point and absorb the forces that the plastic alone could not withstand. After inserting and / or feeding in the metal insert 110 In a plastic injection mold, no additional process is necessary to create a connection point. Furthermore, a complex spring-loaded clamping assembly is not necessary during the plastic injection molding process.

List of reference symbols

110

Metal insert

112

Plastic component

114

Polymer material

116

First face

118

Second face

120

Flange geometry

122

Base body

124

shaft

126

Security area

128

Outer surface

130

Gear geometry

132

Axis of rotation

134

Front side

136

Transition between flange geometry and base body

137

crossing

138

Vertical section at the transition

140

Sloping section at the transition

142

drilling

144

Through hole

146

Entry / exit slope

148

Distal ends of the metal insert

150

Process step a)

152

Process step b)

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

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• DE 202014100008 U1 [0002]
• DE 102009051037 A1 [0002]
• DE 202010017804 U1 [0004]
• DE 19856611 A1 [0005]
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Claims (10)

Metal insert (110) for use in a plastic component (112), the metal insert (110) having a first end face (116) and a second end face (118) each with a flange geometry (120), the flange geometries (120) of the first end face (116) and the second end face (118) are arranged plane-parallel to one another, the metal insert (110) having a cylindrical base body (122) which is arranged between the first end face (116) and the second end face (118), the flange geometries (120) have a diameter which is larger than the diameter of the base body (122), the base body having a shaft (124) and securing area (126), the securing area (126) having a lateral surface (128) with a plurality of polygons Tooth geometries (130), the polygonal tooth geometries (130) along a curve running parallel to an axis of rotation (132) of the base body (122) are ordered. Metal insert (110) according to the preceding claim, wherein a transition (136) between the base body (122) and at least one of the flange geometries (120) has a radius. Metal insert (110) according to the preceding claim, wherein the flange geometries (120) are circular with identical or different diameters. Metal insert (110) according to one of the preceding claims, wherein the metal insert (110) comprises a bore (142) with a thread or a through bore (144). Metal insert (110) according to one of the preceding claims, wherein the toothing geometries (130) run trapezoidally. Metal insert (110) according to one of the preceding claims, wherein the toothing geometries (130) each have at least one element selected from the group consisting of: wedges; Pink; three-dimensional geometries with a trapezoidal cross-section; three-dimensional geometries with a polygonal base; three-dimensional geometries with a cycloid base; three-dimensional geometries with an involute base surface extending to the cylindrical base body. Metal insert (110) according to one of the preceding claims, wherein the toothing geometries (130) are arranged at equal intervals around the jacket surface (128) of the securing area (126). Plastic component (112) comprising at least one metal insert (110) according to one of the preceding claims, wherein the metal insert (110) is embedded in the plastic component (112). Method for producing a plastic component (112) according to the preceding claim, wherein the method comprises the following steps: a) providing a metal insert (110) according to one of the preceding claims relating to a metal insert (110); b) Sheathing the metal insert (110) with at least one polymer material (114) in an injection molding tool using a plastic injection molding process. Method according to the preceding claim, wherein the sheathing comprises the following steps: i. Opening the injection mold; ii. Inserting the metal insert (110); iii. Fixing the metal insert (110); iv. Closing the injection mold; v. Shooting in the polymeric material (114); vi. Opening the injection mold; vii. Ejecting the plastic component (112).

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