WO2021168492A1

WO2021168492A1 - Method for producing a multilayered functional component, and also functional component

Info

Publication number: WO2021168492A1
Application number: PCT/AT2021/060058
Authority: WO
Inventors: Rudolf Gradinger
Original assignee: Lkr Leichtmetallkompetenzzentrum Ranshofen Gmbh
Priority date: 2020-02-28
Filing date: 2021-02-22
Publication date: 2021-09-02
Also published as: AT523652B1; EP4110549A1; AT523652A4

Abstract

The invention relates to a method for producing a multilayered functional component (1), which has an integrated functional element (4), for instance an electrical conductor track, wherein, to form the functional component (1), the functional element (4) is applied to a surface of a base body (3), in particular a metal base body (3), after which at least one covering layer (6) is applied to the surface of the base body so as to cover the functional element (4). To produce the functional component with little effort and with optimized properties for its use, it is provided according to the invention that at least one thin sacrificial layer (5) is arranged in the functional component (1), in order that, when application material is being applied to a portion of the surface of a structure (2) of the functional component (1) to form the functional component (1), a material of the functional-component structure (2) which is located on a side of the thin sacrificial layer (5) facing away from said portion of the surface is protected by the thin surface layer from harmful energy, in particular the supply of heat which is introduced into the functional-component structure (2) when the application material is being applied. The invention also relates to a functional component (1) with an integrated functional element (4).

Description

Process for the production of a multi-layer functional component as well as

Functional component

The invention relates to a method for producing a multi-layer functional component which has an integrated functional element, such as an electrical conductor track, the functional element being applied to a base body surface of a, in particular metallic, base body to form the functional component, after which at least one cover layer is applied to the base body surface which covers the functional element.

Furthermore, the invention relates to a functional component with an integrated functional element, having an, in particular metallic, base body on which the functional element is applied and a cover layer which is applied to the base body so that the functional element is covered by the cover layer.

Various methods for producing multi-layer functional components are known from the prior art, which are based on applying one or more layers, often with build-up welding, to a steel body or its surface in order to form the functional component, with the layers being applied to the steel body prior to application a functional element, for example an electrical conductor track, is applied to the surface of the steel body, so that the functional element is integrated into a structure of the functional component by subsequently applying the layers to the steel body. In this way, the functional component can be equipped with a functionality of the functional element in a practical and robust manner. The layers are usually applied to the steel body using a welding process, usually build-up welding, in order to produce the functional component in a time-efficient manner. Applied layers typically have a thickness between 1 mm and 2 mm. In practical use, when applying application material to a functional component structure of the functional component to form the functional component, care must be taken that the functional component structure or its surface, especially its metallic grain structure and material composition, is not damaged by the application of the application material. a commonly occurring damage to the Functional component structure is kept small, especially since welding processes are usually associated with a high input of damage energy in the form of heat into the functional component structure or its surface. This applies in particular when a layer covering the functional element is formed with the application material in order to keep damage to the functional element as small as possible. Such damage, in particular when it concerns the functional element, usually leads to a lower usability, in particular longevity, of the functional component or undermines a functionality introduced into the functional component with the functional element. In order to reduce the risk of damage, a specific selection and coordination of material used in material layers to be arranged on top of one another is therefore often made, in particular with a focus on a material with which the functional element is or will be formed.

This is where the invention comes into play. The object of the invention is to specify a method of the type mentioned at the outset, with which the functional component can be manufactured with little effort and optimized usability.

Another aim is to specify a functional component of the type mentioned at the outset, which has an optimized usability.

The object is achieved according to the invention by a method of the type mentioned at the outset, if at least one sacrificial thin layer is arranged in the functional component in order, when applying material to a surface section of a functional component structure of the functional component to form the functional component, a functional component material located on a side of the sacrificial thin layer facing away from the surface section to protect the functional component structure with the thin surface layer from damage energy, in particular heat input, which is introduced into the functional component structure when the application material is applied.

The background to the invention is the idea of producing certain material areas or areas of the functional component structure, with which the functional component is formed by applying application material to the functional component structure or its surface, prior to the application of the application material shield associated damage energy introduced into the functional component structure. The application of application material to the functional component structure or its surface is usually carried out by producing a metallurgical connection between the application material and a material of the functional component structure or its surface. In this case, the surface of the functional component structure is usually melted or heated to a temperature above its liquidus temperature, so that heat is introduced into the functional component structure as damage energy, which in particular results in undesirable changes in the material composition of the surface of the functional component or of material layers underneath it can. In the case of build-up welding, which is usually used, the damage energy is primarily a thermal load or heating, in particular melting, of the surface of the functional component structure. If application material is applied in that the application material is accelerated or shot at the surface of the functional component structure, the damage energy is usually kinetic energy which is exerted on the surface. Depending on the application method used, with which application material is applied to the surface of the functional component structure, damage energy can basically be physical, in particular thermal, mechanical, kinetic, electrical and / or chemical energy, which is an undesired influence, in particular destruction or change in material properties , the functional component material causes. An undesired formation of mixed connections between layers or areas of different material compositions, caused by the damage energy introduced, is usually to be regarded as particularly harmful. The damage energy usually arises when the application material is applied to the functional component structure or is introduced into it with an energy source, usually an energy source of the application process.

Functional component structure, also called a semifinished product of the functional component, denotes a functional component in the process of being created, the functional component being formed by applying, in particular further, application material to the functional component structure. The functional component structure thus represents the functional component in different phases of the formation of the functional component, in particular beginning with formation of the base body, via a state in which the functional element is arranged or applied to the base body, right up to the completion of the functional component.

It has been shown that a practical shielding or damping of damage energy can be achieved with one or more sacrificial thin layers arranged in the functional component or the functional component structure of the functional component. The shielding or damping is generally based on the fact that the sacrificial thin layer is damaged instead of a functional component material to be protected with the sacrificial thin layer. It is usually provided that the sacrificial thin layer is designed to shield or attenuate damage energy acting on a sacrificial thin layer surface of the sacrificial thin layer, in particular to absorb and / or compensate and / or reflect in order to be on a side of the surface thin layer facing away from the acting damage energy To protect functional component material of the functional component structure. In particular, damage, in particular destruction, of the sacrificial thin layer is deliberately provided in order to protect a material on which the sacrificial thin layer is arranged or applied when further material or application material is applied to the sacrificial thin layer.

By first applying a sacrificial thin layer to a surface of the functional component structure and then applying application material to the sacrificial thin layer, the surface of the functional component structure can be protected from damage energy associated with the application of the application material, in particular heat input associated with heating. In particular, when the application material is applied, the sacrificial thin layer or its surface is melted or heated to a temperature above its liquidus temperature in order to produce a metallurgical bond. It goes without saying that the sacrificial thin layer or its sacrificial thin layer material is applied to the surface of the functional component structure in such a way that the surface, in particular its material structure or material composition, is influenced as little as possible.

It was found that in practical use thin layers are usually sufficient as sacrificial structures in order to achieve effective shielding or damping of damage energy acting on the sacrificial structure. This can probably be explained by the fact that in the usual with application methods for applying Damage energy effects associated with the application material, surface interactions or boundary layer interactions play a prominent role or absorption and compensation of damage energy can be implemented to a large extent in these. Expediently, it is therefore usually provided that one or more sacrificial thin layers, which are usually applied as surface thin layers, in particular one on top of the other, a functional component material located on a side of the sacrificial thin layer facing away from the surface section of the functional component structure, in particular the functional element, with the sacrificial thin layer or the sacrificial thin layers protect from the damaging energy. In particular, several sacrificial thin layers can be formed directly on top of one another and / or with different thicknesses, the sacrificial thin layers arranged directly on top of one another advantageously being able to be formed with increasing thicknesses, i.e. in each case a further sacrificial thin layer applied directly to another sacrificial thin layer has a greater thickness than that on the this is applied.

Accordingly, it is advantageous if the sacrificial thin layer is arranged, in particular directly, on a functional component material to be protected, preferably a surface of the functional element and / or the base body, or is applied to it.

Depending on the specific application objective, one or more sacrificial thin layers can be arranged in the functional component or the functional component structure or applied to a surface of the functional component structure, preferably the functional element. In particular, the sacrificial thin layers or their material thus become part of the functional component. Depending on the application method with which application material is then generally applied to the sacrificial thin layers to form the functional component, a respective sacrificial thin layer or its material can at least partially form a mixed connection or a metallurgical connection with the application material.

In this way, commonly used application methods or manufacturing methods to apply application material to the functional component structure can continue to be used with little effort. The application material is usually applied to form the functional component or functional element or the base body or the cover layer with the application material. By shielding material areas of the functional component that are particularly sensitive to damage, in particular material areas of the functional element, from the effects of the damage energy, the usefulness or longevity of the functional component can be increased and, in particular, the functional component's susceptibility to faults can be reduced in an operational state. In this way it can be achieved that material arrangements or layer or layer arrangements with damage-sensitive materials can be used to form the functional component by protecting them with one or more sacrificial thin layers, in particular applied to them.

It has proven useful if the at least one sacrificial thin layer is arranged or applied between the functional element and the cover layer and / or between the functional element and the base body surface in order to protect the functional element or the base body surface from damage energy, in particular heat, with the sacrificial thin layer subsequent application of application material to the functional component structure or its surface section to protect. In this way, an interaction between a functional element material and a material of the cover layer or of the base body when the functional element is arranged on the base body surface or when the cover layer is arranged on the functional element can be efficiently reduced. A plurality of sacrificial thin layers are preferably present, one or more of the sacrificial thin layers being arranged between the functional element and the cover layer and / or one or more of the sacrificial thin layers being arranged between the functional element and the base body surface. For this purpose, it is usually provided that the at least one sacrificial thin layer, in particular directly, is arranged or applied to a surface area of the functional element or the base body in order to use the sacrificial thin layer to protect the surface area from damage energy, in particular heat, during a subsequent application of application material to protect the sacrificial film. The application of the application material generally serves to form the functional element or to form the cover layer. The base body and / or the cover layer is usually formed with or from metal or a metal alloy, preferably a transition metal alloy, in particular an iron-based alloy, preferably steel. Depending on the application, the However, the base body and / or the cover layer can also be formed with an aluminum alloy or aluminum-based alloy, copper alloy or copper-based alloy, magnesium alloy or magnesium-based alloy and / or nickel alloy or nickel-based alloy. It goes without saying that the base body and / or the cover layer can in principle be formed from any suitable application alloy known to the person skilled in the art, with metal alloys having proven to be particularly practical.

In particular, it has proven useful for a robust and long-lasting structure if at least a first sacrificial thin layer is applied to the base body surface, after which the functional element is applied to the first sacrificial thin layer, after which at least a second sacrificial thin layer is applied to the functional element, after which on the base body surface and the second sacrificial thin layer, the cover layer is applied. Depending on the application objective, the first sacrificial thin layer or the second sacrificial thin layer can optionally be present or applied. This enables a solid and robust material composite and flexible adaptation of a manufacturing process control, in particular to compensate for inaccuracies and adaptation errors. It goes without saying that it can be favorable here if one or more first or second sacrificial thin layers, in particular stacked or layered one above the other, are arranged or applied to one another. It is preferred if the functional element is formed or applied by applying application material to the functional component structure, in particular the base body surface or the sacrificial thin layer. In this way, a precisely shaped material composite can be implemented flexibly. The functional element is preferably formed by applying material in a flowable, in particular partially liquid or liquid, state to the base body surface or a sacrificial thin layer applied to it. It is favorable if the sacrificial thin layer arranged between the functional element and the base body or between the functional element and the cover layer, i.e. the first sacrificial thin layer and / or the second sacrificial thin layer, is formed with or from the same material or the same material composition, with or from which the functional element or its surface is formed. In this way, a structure or a mode of operation in the use of the functional component is disturbed particularly little. It can be advantageous if, as explained below, an arrangement of a plurality of thin sacrificial layers arranged on top of one another is arranged in each case between the functional element and the base body and / or between the functional element and the cover layer. In particular, the aforementioned first and second sacrificial thin layers are each replaced by such an arrangement. It has proven useful if a sacrificial thin layer adjoining or resting on the functional element is formed with or from the same material or the same material composition with or from which the functional element or its surface is formed, and one or more others Sacrificial thin layers of the arrangement are formed with or from a different material or a different material composition. For example, if the functional element is designed as an electrical conductor, the further sacrificial thin layer can be designed to be electrically non-conductive or electrically insulating. In this way, in addition to the shielding effect, an insulation functionality implemented with the sacrificial thin layers is practicable.

With regard to a thickness of the sacrificial thin layer, it can be seen that it is advantageous for a low-cost production if the thickness of the sacrificial thin layer is made as small as possible, albeit sufficiently thick to enable a pronounced shielding or damping effect, especially since an arrangement or Applying the sacrificial thin layer in or on the functional component structure requires a considerable amount of work, especially since the functional component structure should not be damaged as much as possible. It is advantageous if the sacrificial thin layer is formed with a thickness of less than 30 μm, in particular less than 25 μm, preferably less than 20 μm. As a result, the sacrificial thin layer can be arranged in the functional component with only little disruption of the structure or functionality of the functional component and, as a rule, with little effort. It has been shown that an expedient compromise between a pronounced shielding effect of the sacrificial thin layer and little disruption of the structure or functionality of the functional component can be achieved if the sacrificial thin layer is formed with a thickness between 10 μm and 30 μm, preferably between 10 μm and 20 μm . It goes without saying that an application suitability of a respective used thickness of the sacrificial thin layer depends on a specific application purpose, in particular on the type and extent of the damage energy introduced, a sensitivity to damage of a functional component material to be protected with the sacrificial thin layer and / or a material of the Sacrificial thin film depends. It can be favorable if the sacrificial thin layer has a thickness greater than 1 μm, in particular a thickness between 3 μm and 10 μm, often around 5 μm, in particular if a finely structured functional component, for example with a very thin layer applied to the sacrificial thin layer, is formed. Depending on the application, it can thus be advantageous if the at least one sacrificial thin layer is formed with a thickness between 1 pm and 30 pm, in particular between 5 pm and 25 pm, preferably between 10 pm and 20 pm, particularly preferably between 15 pm and 20 pm will. It goes without saying that different sacrificial thin layers are or can be formed with different thicknesses. For a simple implementation, however, the sacrificial thin layers can also be designed with the same thicknesses. If sacrificial thin layers are arranged, in particular directly, one above the other or applied to one another, it is generally advantageous if a sacrificial thin layer applied first is formed with a smaller thickness than a sacrificial thin layer arranged or applied to it subsequently. This is explained by the fact that the subsequently applied sacrificial thin layer has a shielding effect or an insulating effect for the previously applied sacrificial thin layer. Accordingly, it can be favorable for an effort-optimized production if several sacrificial thin layers form an arrangement of, in particular directly, superimposed or applied sacrificial thin layers . under this arranged sacrificial thin layers of the arrangement. As a rule, such an arrangement is formed with at least 3 sacrificial thin layers, preferably at least 4, particularly preferably at least 5 sacrificial thin layers. As a result, an optimized shielding effect or damping effect can be implemented, in particular if the sacrificial thin layers are formed with different material properties, in particular material compositions. It is practical for this purpose if the arrangement is formed with no more than 7, in particular 10, sacrificial thin layers.

It was found that a particularly pronounced shielding effect of the sacrificial thin layer can be achieved when applying material to the sacrificial thin layer if a material layer directly applied to the sacrificial thin layer is formed with a thickness which is greater than the thickness of the sacrificial thin layer and less than 50 times , in particular less than 30 times, preferably less than 10 times, particularly preferably less than 5 times, the thickness of the sacrificial thin layer. This is especially true when the material layer is the cover layer. In particular, if the application process with which the material is applied to the sacrificial thin layer is a surface-heating or surface-melting manufacturing process, in particular a welding process, preferably a build-up welding process, a high shielding effect can be achieved in this way with the sacrificial thin layer.

For a robust structure, it is usually provided that the cover layer is designed with a thickness greater than 30 μm, usually greater than 50 μm, generally greater than 100 μm. It has proven useful if the cover layer is formed with a thickness between 100 μm and 5 cm, in particular between 250 μm and 5 cm, preferably between 500 μm and 2.5 cm. In this way, a high level of stability and resilience of the functional component can be implemented.

For low-cost production, it is advantageous if the application of the application material, in particular the application of the cover layer and / or the application of the functional element, is implemented with a second application process and the arrangement or application of the sacrificial thin layer is implemented with a first application process, the second Application method is more damaging energy intensive or causes greater damage energy or introduces it into the functional component structure than the first application method. In this way, the functional component can be produced in a time-efficient manner and, at the same time, a low-damage material structure can be implemented in the functional component. In this context, damage energy-intensive usually means that the second application method, in comparison with the first application method, causes damage of a higher damage class when material, in particular application material, is applied to a surface. In particular, this is the case when the second application method, when applying material to a surface, introduces a greater amount of heat or thermal energy into the surface, in particular causes greater heating of the surface than the first application method. As a rule, the first application method and the second application method represent different manufacturing methods. However, it is also conceivable to implement the first application method and the second application method with the same manufacturing method, the manufacturing method depending on implementation as first application method or second application method is operated in such a way that this causes a different damage energy when applying material or application material. For this purpose, the manufacturing process can be operated in different energy ranges, for example. The first application process is practicable with or as a cold gas spray process and / or plasma spray process. For low-cost manufacture, it is favorable if the second application process is implemented with or as a welding process and / or soldering process and / or casting process and / or an additive or generative manufacturing process.

In practice, it is advantageous if, when applying the sacrificial thin layer to a surface area of the functional component structure, in particular the surface area of the functional element or base body, a surface area material of the surface area is preferred up to a maximum of 0.5 times, in particular 0.3 times 0.1 times, a liquidus temperature of the surface area material is heated. In this way, negative influence on the surface area material can be reduced to a great extent. It is accordingly advantageous if the first application method is implemented in this way.

It is preferred if the sacrificial thin layer is formed or applied by accelerating and selectively guided, in particular blown, particles present in powder form onto a surface of the functional component structure, in particular a surface area of the functional element or base body, so that the particles upon impact Form an adhesive sacrificial thin layer on the surface. This enables the sacrificial thin layer to be arranged in the functional component or applied to the functional component structure with particularly little damage, since the sacrificial thin layer can be applied without introducing a significant amount of damage energy, in particular thermal energy, into the functional component structure or its surface, in particular without melting the surface. It is correspondingly favorable if the first application method is implemented in this way. It has proven useful if the particles are injected into a flow of a transport gas in order to accelerate the particles and guide them onto the surface of the functional component structure. The transport gas is usually formed with or from argon, nitrogen, hydrogen and / or helium. Usually the transport gas here at supersonic speed and is usually heated up. The transport gas usually has a temperature of several hundred degrees Celsius. Alternatively or cumulatively, it can be practical if the particles are accelerated with an electric and / or magnetic field in order to guide the particles onto the surface of the functional component structure. In this way, the sacrificial thin layer can be applied to the surface of the functional component structure with particularly little damage. It is favorable if the particles are heated, preferably at least partially or completely melted, and then passed onto the surface of the functional component. Usually, the particles are heated to a temperature between 0.2 times, in particular 0.5 times, preferably 0.8 times, a liquidus temperature of the particles or their material and the liquidus temperature of the particles. However, it can also be beneficial to heat the particles above their liquidus temperature in order to at least partially or completely melt the particles. A particularly robust sacrificial thin layer can be generated if the particles are heated in the transport gas, in particular in the aforementioned manner, preferably at least partially or completely, melted and then passed onto the surface of the functional component. For this purpose, it is advantageous if the transport gas is converted into a plasma state of the transport gas before the particles are injected into the transport gas, for example with an arc, after which the particles are injected into the transport gas. In particular, the thin sacrificial layer can be applied using a cold gas spray method or plasma spray method or flame spraying.

In order to form a robust sacrificial thin layer, which in particular has a high shielding effect, it is advantageous if the particles preferably have an average particle size, in particular a spherical diameter equivalent to volume, between 0.1 μm and 25 μm, in particular between 0.5 μm and 20 μm between 2 pm and 10 pm. The sacrificial thin layer can thus be designed to be particularly tight and adherent.

Alternatively or cumulatively, it is advantageous if the sacrificial thin layer is formed or applied using an additive or generative manufacturing method, in particular the first application method is designed in this way. This enables a particularly structurally fine application of the sacrificial thin layer. Known additive manufacturing processes such as laser sintering, selective laser melting or Electron beam melting can be used. In particular, the sacrificial thin layer can be formed with a powder, usually with fusing or sintering of particles of the powder, the powder preferably being formed with or by particles of the aforementioned characteristics. It can also be practicable if the application material, in particular to form the cover layer or the functional element, is applied using such an application method, in particular the second application method is designed in this way.

For low-cost manufacture, it has proven useful if the application material, in particular to form the cover layer or the functional element, is applied using an application process that involves substantial heating, in particular melting, of the application material and / or a surface or surface section of the Functional component structure to which the application material is applied causes. In practice, it is useful if, when applying the application material to the surface of the functional component structure, the application material and / or a surface material of the surface are each more than 0.5 times, in particular 0.8 times, a liquidus temperature of the application material or surface material is heated. This is preferably done with a welding process, in particular with build-up welding. It is favorable if the second application method is implemented in this way. The application material is usually applied to a surface of the functional component structure, preferably directly to the sacrificial thin layer or its surface. The aforementioned applies in particular to the surface of the sacrificial thin layer when application material is applied to it. In this way, the functional component can be manufactured in a robust and time-efficient manner, with damage energy associated with the heating being able to be efficiently compensated or attenuated with damage to the sacrificial thin layer.

It is advantageous if the sacrificial thin layer is arranged in such a way that it essentially replaces an entire interface between the functional element and the cover layer and / or between the functional element and the base body. In this way, the functional element with the sacrificial thin layer is efficiently protected. In technical terms, boundary surface denotes that contact surface at which different component structures, in particular the functional element and the cover layer or the functional element and the base body, abut one another or adjoin one another. It has proven useful if the sacrificial thin layer is arranged in such a way that it selectively only replaces essentially the entire interface between the functional element and the cover layer and / or between the functional element and the base body. In this way, the functional element is protected in a targeted manner. The functional component can thus be produced in a time-efficient and cost-effective manner with a high level of protection for the functional element, especially since the formation of the sacrificial thin layer generally requires a large amount of time.

Functional element usually refers to a component that has a functionality tailored to the purpose, in particular a functionality that goes beyond a normal carrying function. In most cases, it is an electrical or electronic functionality and / or a thermal, in particular heat-conducting, functionality. A high degree of practicality can be achieved if the functional element is designed with or as an information conductor and / or energy conductor and / or heat conductor, preferably electrical conductor or light conductor, in order to conduct a corresponding physical variable with the functional material, in particular to form a corresponding circuit or to act as part of such. For example, it has proven useful if the functional element is designed as a signal conductor in order to transmit electrical signals or light signals via the functional element. Alternatively or cumulatively, the functional element can be designed with or as a sensor, for example for measuring a temperature, a pressure, a strain, a mechanical tension, an electrical voltage and / or an acceleration, in order to measure a corresponding measured variable. The functional element can form an electrical or electronic circuit or be part of such a circuit. It is practical if the functional element is designed with or as a thermocouple for temperature measurement. An advantageous implementation can be achieved if the functional element is designed with or as a Peltier element in order to heat and / or cool the functional component. Depending on the application objective, the functional element can be designed with different functionalities in a corresponding manner.

The functional element can be formed with or from metal or a metal alloy, preferably a transition metal alloy, in particular an iron-based alloy and / or copper-based alloy and / or silver-based alloy and / or gold-based alloy be. Depending on the intended use, the functional element can, however, also be formed with an aluminum alloy or aluminum-based alloy and / or nickel alloy or nickel-based alloy or other application alloy. For example, it can be expedient to form the functional element with or from constantan. This is particularly true when the functional element is designed as an electrical conductor and / or heat conductor. It can be practical if the functional element is formed with or from plastic and / or a ceramic material. For example, to design the functional element as a heat conductor or light guide. Silicon compounds in particular have proven to be practical. It goes without saying that a material of the functional element is dependent on a specific application purpose of the functional component or functional element.

As a rule, it is expediently provided that the functional component is designed with at least one first coupling interface in order to connect the functional component to a functional device, for example a further functional component, for the intended use of the functional component in such a way that the functional element can be functionally resp. is coupled to a second coupling interface of the functional device in accordance with a functionality of the functional element. The second coupling interface is expediently designed, as a rule, in a shape corresponding to the first coupling interface, in order to establish direct contact, in particular press contact, between the coupling interfaces. The first coupling interface and the second coupling interface can be designed identically or identically. The first coupling interface is usually arranged on an outer side of the functional component, usually designed as part of an outer surface of the functional component. The coupling interface is usually designed as part of the functional element or connected to it. It is practical if the functional element is designed in such a way that it extends in at least one direction up to at least one outer side or outer surface of the functional component in order to form the at least first coupling interface. For a high level of usability, it is advantageous if several first coupling interfaces are provided. If the functional element is formed with or as an electrical conductor, it is generally provided, for example, that the first coupling interface is designed as an electrical contact, in order to connect the first coupling interface with a second coupling interface of the functional device designed as an electrical contact to connect electrically. It is preferably provided that the functional device is designed as a further functional component, the functional components being connectable to one another in such a way that their functional elements can be functionally coupled or coupled to one another via the respective coupling interfaces.

It is advantageous if the functional element is at least partially, preferably essentially completely, removed from the functional component structure or from the functional component after the covering layer has been applied, so that a cavity or a hollow space is formed in the functional component. The functional element thus has the functionality of a mold core in order to produce one or more cavities or cavities in the functional component in a targeted manner. It goes without saying that a shape or shape of the cavity or cavity is then usually essentially a shape or shape.

The shape of the functional element corresponds or can correspond. In this way, for example, channels, in particular cooling channels and / or heating channels, can be particularly practically formed in the functional component in order to conduct a medium through the channels when the functional component is in use, in particular for cooling or heating the functional component. If the sacrificial thin layer or one of the sacrificial thin layers adjoining the functional element, in particular between the functional element and the cover layer and / or between the functional element and the base body, is or is applied to the functional element, the sacrificial thin layer usually forms after the functional element has been removed a wall surface delimiting the cavity or the cavity. The properties, in particular material properties, of the sacrificial thin layer are therefore of particular importance with regard to an application functionality of the functional component. For this purpose, it has proven to be useful if the functional element is at least partially, preferably essentially, completely loosened with a washout agent after the cover layer has been applied in order to remove or remove the functional element from the functional component structure or the functional component, at least partially or essentially completely. to wash out. A material of the functional element can thereby be converted into a flowable, in particular liquid, state and, in particular, can be derived from an interior of the functional component. As a rule, it is provided that the functional element extends as far as an outside of the functional component structure or the functional component, so that the functional element can be acted upon with washout agent in a simple manner. Alternatively or cumulatively, at least one Bore are introduced into the functional component structure in order to act on the functional element with washout agent. It is useful if the functional element is formed with or from a material which can be or dissolved with water and / or acetone. It is practicable for a robust construction of the functional component if the functional element is formed with or from plastic or plastic composite material which is detachable, in particular with water and / or acetone.

For example, the functional element can be formed with or from polyvinyl acetate, also called PVA or PVAC, and / or polyvinyl alcohol, also called PVAL or PVOH. It has proven useful if the functional element is formed with inert additive particles, in particular with a proportion of more than 50% by weight, preferably more than 70% by weight, particularly preferably more than 90% by weight. This enables a simple loosening or dissolving of the functional element. The additive particles preferably have an average additive particle size, in particular a volume-equivalent spherical diameter, between 50 μm and 500 μm, in particular between 100 μm and 300 μm, preferably between 150 μm and 250 μm. It has proven useful if the additive particles are formed with or as sand, in particular quartz sand. The additive particles are preferably designed as molding sand, usually formed with quartz sand and a binding agent for connecting the quartz sand.

It goes without saying that it is favorable for a high level of operational functionality if a plurality of functional elements are arranged in the functional component, in particular in the manner described above. In particular, one or more further functional elements can be arranged between layers of the base body and / or between cover layers applied to the base body. It is favorable if the plurality of functional elements are designed differently, in particular in such a way that they have different functionalities, for example corresponding to the aforementioned training options. It can be expedient if the plurality of functional elements are coupled to one another in order to implement a common functionality when the functional component is in use. For this purpose, the functional elements can, for example, form or be part of an aforementioned line circuit. In order to develop a high level of robustness and operational capability, it is correspondingly favorable if further, in particular all, functional elements are protected with one or more sacrificial thin layers. This can be done as described in this document implementation options described. One or more thin sacrificial layers are preferably applied to the surfaces of the further functional element or elements in order to protect them from damage energy introduced into the functional component structure during the formation of the functional component.

In order to optimize the usability of the functional component, it is advantageous if the sacrificial thin layer is designed in a manner that is matched to an application objective of the functional component or functional element. For this purpose, it can be advantageous if the sacrificial thin layer is designed to be electrically non-conductive or electrically insulating. Depending on the intended use, the sacrificial thin layer can be formed in an electrically conductive manner, in particular with or from metal, usually copper, silver, aluminum and / or gold. In particular, if the functional element is designed as an electrical conductor, it is advantageous if one or more sacrificial thin layers that are in contact with the functional element when the functional component is in use or that are applied to the functional element are designed to be electrically insulating. The sacrificial thin layer can thus act as electrical insulation for the functional element. It goes without saying that for this purpose the sacrificial thin layer is made at least so thick that these or their aforementioned properties are not destroyed during a subsequent application of application material to the sacrificial thin layer. Depending on the application method, in particular the thicknesses of the sacrificial thin layer specified above have proven to be practicable for this purpose.

It is practical if the sacrificial thin layer is formed in such a way that a thermal conductivity of the sacrificial thin layer is less than an average thermal conductivity of the functional component, in particular of the functional element and / or base body and / or the cover layer or their respective materials. In this way, the sacrificial thin layer can be designed as a heat resistance layer or thermal insulation, for example in order to influence or predetermine the conduction of a heat flow or the propagation of heat in the functional component. If the functional element is designed as a heat conductor, it can be favorable, depending on the application, if the sacrificial thin layer has a high thermal conductivity, for example to conduct heat via the functional element through the sacrificial thin layer into the base body and / or the cover layers, or a low thermal conductivity, for example to Heat by means of the functional element with little heat loss or Has to pass heat dissipation through the sacrificial thin layer to the base body and / or the cover layers. If the sacrificial thin layer is to be designed to be thermally conductive or with high thermal conductivity, it is advantageous if an average thermal conductivity of the sacrificial thin layer is greater than 3 W / (m K), in particular greater than 10 W / (m K), preferably greater than 50 W / ( m K), particularly preferably greater than 100 W / (m K). If the sacrificial thin layer is to be designed to be thermally insulating or with low thermal conductivity, it is advantageous if an average thermal conductivity of the sacrificial thin layer is less than 3 W / (m K), in particular less than 1 W / (m K), preferably less than 0.5 W. / (m K), particularly preferably less than 0.1 W / (m K).

The sacrificial thin layer can be formed with or from metal or a metal alloy, preferably a transition metal alloy, in particular an iron-based alloy and / or copper-based alloy. It has proven useful if the sacrificial thin layer is formed with or from, in particular inert, ceramic material and / or with or from, in particular inert, plastic. In this way, in particular the aforementioned electrically insulating and / or thermally insulating properties of the sacrificial thin layer can be implemented in a practicable manner. This is particularly true when the sacrificial thin layer adjoins or is applied to the functional element. In particular, if the functional element is removed or detached, as explained above, in order to form a cavity or a cavity, it is advantageous if the sacrificial thin layer is formed in this way.

It is favorable if the sacrificial thin layer is designed or formed with a sacrificial thin layer material in such a way that in a state in which the sacrificial thin layer in the functional component or the functional component structure is between a first material of the functional component structure and a second material of the functional component structure, which are opposite one another Sides of the sacrificial thin layer bear against the sacrificial thin layer or its sacrificial thin layer material, a diffusion tendency of sacrificial thin layer material in each case into the first material and / or second material or a diffusion tendency in each case of first material and / or second material in sacrificial thin layer material is smaller than a diffusion tendency in each case of the first material into the second material or a tendency to diffuse in each case of the second material into the first material in a state in which the first material and second material are in direct contact with one another. It is preferred if a diffusion tendency of sacrificial thin-film material in each case into the first material and second material is smaller than a diffusion tendency of the first material into the second material or a diffusion tendency of the second material into the first material in a state in which the first material and second material are in direct contact with one another. The above can only apply to the respective main elements and / or secondary elements of the respective materials. In this way, a finely structured structural separation of different materials of the functional component or its components can be implemented with the sacrificial thin layer.

It can be advantageous if several thin sacrificial layers are arranged or applied to one another, in particular directly, one above the other or one on top of the other in the functional component. In this way, a particularly aforementioned arrangement of a plurality of sacrificial thin layers applied one on top of the other can advantageously be implemented. The sacrificial thin layers can be arranged so as to overlap one another, in particular stacked or layered one on top of the other. As a result, a particularly high shielding effect can be implemented and / or, depending on the specific design of the sacrificial thin layers, their properties can be used in combination. In particular, different sacrificial thin layers can be formed with or from different materials, in particular material compositions. For example, several sacrificial thin layers arranged one above the other can be designed to be electrically insulating in order to implement pronounced electrical insulation in the functional component. It can be expedient, for example, for an electrically conductive sacrificial thin layer to be applied to an electrically non-conductive or electrically insulating sacrificial thin layer, or vice versa. The electrically non-conductive sacrificial thin layer then has the additional functionality of insulation. It is advantageous if between the functional element and the base body or between the functional element and the cover layer there is in each case an arrangement of several sacrificial thin layers arranged or applied one on top of the other. The arrangement or a sacrificial thin layer of the arrangement usually adjoins or rests on the functional element. It is favorable if a sacrificial thin layer of the arrangement adjoining or resting on the functional element, for example the sacrificial thin layer or that sacrificial thin layer applied to the functional element which the functional element is applied, is formed with or from the same material or the same material composition as the functional element.

As a result, the respective sacrificial thin layer and the functional element can be connected to one another or applied to one another with particularly little interference. Expediently, at least one further sacrificial thin layer, or if necessary several further sacrificial thin layers, of the arrangement can be formed with a different material or a different material composition, in particular matched to a functionality of the functional element. If the functional element is designed as an electrical conductor, it has proven useful if the further sacrificial thin layer of the arrangement is designed to be electrically non-conductive or electrically insulating. In this way, in addition to a shielding effect of the sacrificial thin layers of the arrangement, insulation of the functional element can be implemented. Depending on the specific embodiment, it can be advantageous if further sacrificial thin layers of the arrangement are designed to be thermally conductive or thermally insulating or electrically conductive or electrically non-conductive. The respective arrangement of sacrificial thin layers, as already explained above, can expediently be formed with 2, 3 or more sacrificial thin layers arranged on top of one another, but generally less than 10 sacrificial thin layers.

As stated above, it is advantageous if a plurality of sacrificial thin layers, in particular directly, are arranged one above the other or are applied to one another in order to form an arrangement of sacrificial thin layers, that is to say a sacrificial thin layer arrangement. For an efficient shielding effect, it is advantageous if a subsequent sacrificial thin layer of the sacrificial thin layer arrangement has a thickness which is greater than a thickness of one, in particular several, preferably all, other sacrificial thin layers of the sacrificial thin layer arrangement on which the subsequent sacrificial thin layer, in particular directly, is arranged or is upset. This preferably applies to several, in particular all, sacrificial thin layers of the sacrificial thin layer arrangement in relation to that sacrificial thin layer (s) to which it is applied. In this way, a robust arrangement of sacrificial thin layers with little damage to functional component material, in particular functional element material, can be formed, since a subsequent sacrificial thin layer of the sacrificial thin layer arrangement protects a sacrificial thin layer of the sacrificial thin layer arrangement arranged in front of it. In this case, different sacrificial thin layers can expediently be included in the sacrificial thin-layer arrangement different sacrificial thin-film material are formed and / or different application methods, in particular different first application methods, are implemented. It goes without saying that it is advantageous if the arrangement of the sacrificial thin layers or the sacrificial thin layer arrangement is aligned in such a way that a subsequent sacrificial thin layer of the sacrificial thin layer arrangement on a side facing away from the functional component material to be protected or the functional element of at least one of the subsequent sacrificial thin layer, in particular directly, upstream sacrificial thin layer of the sacrificial thin layer arrangement is arranged or of at least one sacrificial thin layer on which the subsequent sacrificial thin layer, in particular directly, is applied. For example, the sacrificial thin-layer arrangement is designed or aligned in such a way that a first sacrificial thin layer of the sacrificial thin-layer arrangement is formed with a first, usually small, thickness and one or more subsequent sacrificial thin layers, which are arranged on a side of the first sacrificial thin layer facing away from the functional element, have a greater thickness as the first sacrificial film.

For a robust and practicable structure, it is expedient if the thicknesses of the sacrificial thin layers of the sacrificial thin-layer arrangement arranged on top of one another have increasing thicknesses or represent a positive gradient. The gradient can in particular be designed to increase in an essentially linear manner in order to implement a structure that is both time-efficient and robust. A particularly time-efficient production can be achieved if the gradient essentially represents an exponential function or power function. For a high protective effect, the arrangement is usually oriented in such a way that the gradient points in the direction of a side of the sacrificial thin-layer arrangement facing away from the functional element or from the functional component material to be protected or the sacrificial thin-layer arrangement has increasing thicknesses of its sacrificial thin layers in this direction. Depending on the specific structure, it can also be expedient if the gradient points in an analogous manner in the opposite direction, in particular points in the direction of a side of the sacrificial thin-film arrangement facing the functional element, or if the sacrificial thin-film arrangement has increasing thicknesses in this direction. Depending on the application, it can be expedient to form the sacrificial thin-layer arrangement with up to 100 sacrificial thin layers, in particular up to 75, mostly up to 50, usually up to 25 sacrificial thin layers. It is practical if the sacrificial thin layer arrangement has between 2 and 15 sacrificial thin layers, in particular between 3 and 12, preferably fewer than 10, particularly preferably less than 7, sacrificial thin layers.

It is favorable if the at least one sacrificial thin layer or a plurality of sacrificial thin layers are arranged in the functional body in such a way that the functional element is essentially completely surrounded by sacrificial thin layers. The thin sacrificial layers are expediently arranged in contact with the functional element or its surface or applied to the functional element. In this way, a particularly pronounced protection of the functional element or its functionality can be achieved. It is advantageous if several thin sacrificial layers are arranged directly on top of one another or applied to one another. The thin sacrificial layers then form a multilayer cover, whereby the functional element is particularly protected.

For a robust structure, it is practical if the functional element is at least partially, in particular completely, arranged sunk in the base body. In this way, the functional element is structurally protected by the base body. For this purpose, it is expedient if the base body has a depression or groove in which the functional element is at least partially, in particular completely, sunk. As shown above, it can be advantageous if at least one sacrificial thin layer is arranged between the base body and the functional element. It is then practical if the sacrificial thin layer is applied to one or more recess walls or groove walls which delimit the recess or groove. It goes without saying that this usually takes place before the functional element is inserted into or formed in the recess or groove. In order to achieve a high level of robustness and resistance, it is usually provided that the base body and / or the cover layer is or will be formed with or from metal, in particular an iron-based alloy, preferably steel. For a high level of robustness and resistance of the functional component in use, it is advantageous if several cover layers are applied to the base body surface or the at least one cover layer is formed with several cover sublayers. Different, in particular adjoining, cover layers or cover sub-layers are preferably formed with a different material composition. In this way, an outer surface of the functional component formed with the cover layer or layers can be matched to a particular application. Alternatively or cumulatively, it is useful for a high level of robustness if the base body is formed with one or more base body layers. Different, in particular adjoining, base body layers are usually formed with different material compositions.

The aim of the invention is achieved by a functional component of the type mentioned at the outset, the functional component being able to be produced in particular with a method according to the invention, the functional component having an, in particular metallic, base body on which the functional element is applied and a cover layer which is placed on the base body is applied so that the functional element is covered by the cover layer, with at least one sacrificial thin layer being arranged between the functional element and the cover layer and / or between the functional element and the base body in order to predefine or to define an interaction between a functional element material and a base body material or cover layer material impede.

As explained above, such a functional component can be produced in a manner that is easy to use and that is optimized for use. In addition, through the at least one sacrificial thin layer, an interaction between the functional element material of the functional element and the base body material of the base body or cover layer material of the cover layer, in particular when the functional component is used as intended, can be predefined or reduced or prevented in a defined manner. Depending on the specific design of the sacrificial thin layer, it can functionally separate the functional element from the base body or the cover layer or allow a defined interaction. Thus, the sacrificial thin layer can be designed as a thermal resistance layer, the thermal conductivity of which is less than an average thermal conductivity of the functional element and / or of the base body. Alternatively or cumulatively, the sacrificial thin layer can be designed to be electrically insulating or electrically conductive. A respective specific design and arrangement of the at least one sacrificial thin layer depends on a respective intended use of the functional component.

Such a functional component can be produced in a simple and practicable manner using a method according to the invention. It goes without saying that the functional component according to the invention can be designed in accordance with or analogously to the features, advantages and effects which are described in the context of a method according to the invention for producing a functional component, in particular above. The same applies analogously to the method according to the invention with regard to a functional component according to the invention, in particular described below.

Further features, advantages and effects result from the exemplary embodiments presented below. In the drawings to which reference is made:

1 to 5 are schematic representations of different manufacturing states of a functional component in a cross section of the functional component;

6 shows a schematic representation of a further functional component with several sacrificial thin layers arranged on top of one another in a cross section;

7 shows a schematic representation of a further functional component with a plurality of cover layers in a cross section; 8 shows a schematic representation of a further functional component with a differently designed functional element in a cross section;

9 shows a schematic representation of a further functional component with a functional element according to FIG. 8 in a cross section;

FIG. 10 shows a schematic representation of a further functional component with a functional element according to FIG. 9 with several sacrificial thin layers arranged on top of one another in a cross section;

11 shows a schematic representation of a further functional component with a functional element in a cross section; FIG. 12 shows a schematic representation of the functional component of FIG. 11 with a modified structure in a cross section.

1 to 5 show schematic representations of different manufacturing states in the manufacture of a functional component 1. The functional component 1 or a functional component structure 2 of the functional component 1, which denotes a functional component 1 that is being formed or a semi-finished product of the functional component 1 each shown schematically in a cross section. Provision is made here for a functional element 4 to be integrated into the functional component 1 or a functional component body of the functional component 1 in order to provide the functional component 1 with a functionality of the functional element 4 for the production of the functional component 1. For this purpose, the functional component body usually comprises a base body 3 and one or more cover layers 6, which are applied to the base body 3, the functional element 4 being arranged between the base body 3 and the cover layers 6 in order to integrate the functional element 4 into the functional component 1. Fig. 1 shows a base body 3, in which a groove 7 is made for receiving a functional element 4, usually using a machining process, usually milling. Since the functional element 4 is at least partially, preferably completely, sunk into the groove 7, it is protected by a structure of the base body 3 that is usually designed to be resistant. The base body 3 is preferably formed with or from a steel alloy in order to ensure a robust construction of the functional component 1. In order to protect the base body surface or a surface section of the base body surface on which the functional element 4 is to be arranged from damage energy when the application material of the functional element 4 is applied to the base body surface, at least one sacrificial thin layer 5 is applied to the base body surface or the surface section, so that the sacrificial thin layer 5 is positioned between the base body surface and the functional element 4, shown in FIG . For this purpose, the sacrificial thin layer 5 is applied to the groove walls of the groove 7, preferably in such a way that an entire interface between the functional element 4 and the base body 3 with the sacrificial thin layer 5 is replaced. It has proven useful if the sacrificial thin layer 5 is formed with a thickness D between 10 μm and 30 μm. In order to prevent damage to the base body 3 when the sacrificial thin layer 5 is applied to the base body 3 as far as possible, the sacrificial thin layer 5 is preferably applied by accelerating particles present in powder form and guiding them onto the surface or groove walls of the base body 3, so that the particles at Form a dense and adhesive sacrificial thin layer 5 upon impact. Cold gas spraying is usually used as the application method for this purpose. As a result, the sacrificial thin layer 5 can be applied without significant impairment of the surface of the base body 3 or, in particular, without causing significant material mixing. The functional element 4 is then arranged on the base body 3 or applied to the sacrificial thin layer 5 applied to the base body 3. In this case, it is now possible to proceed with reduced consideration of introducing damage energy into the functional component structure 2 and, in particular, to use a more damage-energy-intensive application method, especially since the base body surface is protected with the sacrificial thin layer 5. The functional element 4 is preferably applied to the sacrificial thin layer 5 in a flowable form or with at least partial melting of the functional element material, in particular in a materially bonded manner. For this purpose, a casting process or an additive or generative process, in particular a build-up welding process, is usually used. 3 shows the functional element 4 in a state applied to the base body 3 or the sacrificial thin layer 5, the functional element 4 advantageously being arranged at least partially in the groove 7. In order to protect the functional element 4 or its functional element surface from damage energy when at least one cover layer 6 is applied to the functional component structure 2 or the functional element 4, at least one further sacrificial thin layer 5 is applied to the functional element 4, so that the sacrificial thin layer 5 is between the functional element 4 and the cover layer 6, shown in FIG. The further sacrificial thin layer 5 is advantageously applied using an aforementioned application method for applying the aforementioned sacrificial thin layer 5 arranged between the base body 3 and the functional element 4. Then at least one Cover layer 6 applied to the base body surface so that the functional element 4 is covered with the cover layer 6, shown in FIG. 5. As a result, the functional element 4 is robustly and resiliently integrated into the functional component 1 and protected from external loads during use. 5 shows an example of an advantageous embodiment variant of the functional component 1.

The functional element 4 can be designed, for example, as an electrical conductor or as a heat conductor. Depending on the design or application objective of the functional element 4, it can be advantageous if the sacrificial thin layers 5 are designed to be electrically conductive or electrically non-conductive or electrically insulating or to be designed to be heat-conducting or heat-insulating. If the functional element 4 is designed as an electrical conductor, it is usually expedient if sacrificial thin layers 5 in contact with the functional element 4 are designed to be electrically insulating. Depending on the application objectives, a plurality of, in particular the aforementioned, sacrificial thin layers 5 can be applied to the functional element 4 or the functional element 4 in a contacting manner. The sacrificial thin layers 5 can be formed with or from different material compositions in order to adapt the sacrificial thin layers 5 advantageously to a functionality of the functional element 4. The thin sacrificial layers 5 can be applied to one another, in particular stacked or layered or arranged so as to overlap one another.

6 shows a schematic representation of a further functional component 1 in a cross section. The functional component 1 can advantageously be constructed essentially the same as the functional component 1 in FIGS. 1 to 5 and with corresponding features, advantages and effects. This applies analogously in the opposite direction. In contrast to this, the functional component 1 of FIG. 6 has an additional sacrificial thin layer 5 between the functional element 4 and the cover layer 6. By arranging several thin sacrificial layers 5 between the functional element 4 and the cover layer 6, preferably overlapping one another or stacked one on top of the other, a particularly pronounced shielding or damping of damaging energy acting upon application of the cover layer 6 can be achieved. It goes without saying that, in principle, further additional, in particular overlapping or superimposed, sacrificial thin layers 5 can be provided between the functional element 4 and the cover layer 6 in order to provide particularly robust shielding to achieve or attenuation of damage energy, although this is usually associated with a considerable amount of work.

7 shows a schematic representation of a further functional component 1 in a cross section. The functional component 1 can advantageously be constructed essentially the same as the functional component 1 in FIGS. 1 to 5 or 6 and with corresponding features, advantages and effects. This applies analogously in the opposite direction. In contrast to the functional component 1 of FIG. 6, the functional component 1 of FIG. 7 has a plurality of cover layers 6 arranged one above the other or applied to one another, which are applied to the base body structure so that they cover the functional element 4. In this way, the functional element 4, in particular its surface, can be designed specifically tailored to a particular application of the functional element 4. Usually, the different cover layers 6 are formed with cover layer material of different material properties. It can be advantageous if one or more sacrificial thin layers 5 are arranged between two cover layers 6 or a sacrificial thin layer 5 is applied to a cover layer surface, in particular in the aforementioned manner, in order to protect it or to reduce or reduce an interaction between the cover layers 6. to pretend.

8 shows a schematic representation of a further functional component 1 in a cross section. The functional component 1 can advantageously be constructed essentially the same as the functional component 1 in FIGS. 1 to 5 or 6 or 7 and with corresponding features, advantages and effects. This applies analogously in the opposite direction. In contrast to the functional component 1 of FIG. 7, in the functional component 1 of FIG. 8, no sacrificial thin layer 5 is arranged between the functional element 4 and the base body 3. In addition, as can be seen in FIG. 8, it can be provided that the base body 3 is not formed with a groove 7. The base body 3 is advantageously formed with several base body layers 9. It can be favorable if one or more thin sacrificial layers 5 are arranged between base body layers 9 or are applied to a base body layer 9 in order to protect the base body layer or to reduce or specify an interaction between the base body layers 9. It can also be provided that the cover layer 6 is formed with a plurality of cover sub-layers 8, the cover sub-layers 8 having different material properties exhibit. One or more thin sacrificial layers 5 can then be arranged between cover sub-layers 8 or applied to a base body layer in order to protect the cover sub-layer 8 or to reduce or specify an interaction between the cover sub-layers 8. As can be seen in FIG. 8, a sacrificial thin layer 5 is advantageously arranged between the functional element 4 and the cover layer 6 or the cover sublayers 8, in particular in the aforementioned manner, or applied to the functional element 4 in order to protect the functional element 4.

9 shows a schematic representation of a further functional component 1 in a cross section. The functional component 1 can advantageously be constructed essentially in accordance with the functional component 1 of FIGS. 1 to 5 or 6 to 8 and with corresponding features, advantages and effects. This applies analogously in the opposite direction. The functional component of FIG. 9 is constructed essentially in accordance with the functional component of FIG. 8. In contrast to the functional component 1 of FIG. 8, in the functional component 1 of FIG. 9, a further sacrificial thin layer 5 is arranged between the functional element 4 and the base body 3. A sacrificial thin layer 5 is thus advantageously arranged adjacent to the functional element 4 or applied to the functional element 4 or the base body 3 both between the functional element 4 and the cover layer 6 and between the functional element 4 and the base body 3. It is favorable if the sacrificial thin layers 5 are arranged in such a way that they essentially replace an entire interface between the functional element 4 and the cover layer 6 and between the functional element 4 and the base body 3. The functional element 4 is thus, as can be seen in FIG. 9, essentially completely enveloped by the sacrificial thin layers 5.

Fig. 10 shows a schematic representation of a further functional component 1 in a cross section. The functional component 1 can advantageously be constructed essentially in accordance with the functional component 1 of FIGS. 1 to 5 or 6 to 9 and with corresponding features, advantages and effects. This applies analogously in the opposite direction. The functional component 1 of FIG. 10 is constructed essentially in accordance with the functional component 1 of FIG. 9. In contrast to the functional component 1 of FIG. 9, in the functional component 1 of FIG. 10 there is in each case an arrangement 10 of several superimposed sacrificial thin layers 5 between the functional element 4 and the base body 3 or between the functional element 4 and the cover layer 6 or applied to the base body 3 or the functional element 4. The various sacrificial thin layers 5 in the arrangement 10 are usually formed with different material compositions. In order to achieve a robust composite, it is advantageous if a sacrificial thin layer 5 of the respective arrangement 10 adjoining or resting on the functional element 4, for example the sacrificial thin layer 5 applied to the functional element 4 or that sacrificial thin layer 5 to which the functional element 4 is applied, is formed with or from the same material or the same material composition as the functional element 4. Expediently, at least one further sacrificial thin layer 5, or optionally several further sacrificial thin layers 5, of the respective arrangement 10 can be made with a different material or a different material composition are designed, in particular matched to a functionality of the functional element 4. If the functional element 4 is designed as an electrical conductor, it has proven useful if the further sacrificial thin layer 5 of the arrangement 10 is designed to be electrically non-conductive or electrically insulating. In this way, in addition to a shielding effect of the sacrificial thin layers 5 of the arrangement 10, an insulation of the functional element 4 can be implemented. Depending on the specific embodiment, it can be advantageous if the further sacrificial thin layer 5 of the arrangement or possibly other further sacrificial thin layers 5 of the arrangement 10 are designed to be thermally conductive or thermally insulating or electrically conductive or electrically non-conductive.

11 shows a schematic representation of a further functional component 1 in a cross section. The functional component 1 can advantageously be designed in accordance with the features and effects of the functional component 1 of FIGS. 1 to 5 or 6 to 10. This applies analogously in the opposite direction. The functional component 1 of FIG. 11 is constructed essentially in accordance with the functional component 1 of FIG. 8, in contrast to this, an arrangement 10 of several sacrificial thin layers 5 arranged on top of one another being arranged between the functional element (4) and the cover layer 6 or on the functional element 4 is applied. The various sacrificial thin layers 5 in the arrangement 10 can be formed with material compositions that differ from one another, for example as explained above in the context of FIG. 10. The sacrificial thin layers 5 of the arrangement 10 can, as shown in FIG. 11, advantageously in this way on top of one another be arranged so that a subsequent sacrificial thin layer 5 of the arrangement 10 has a greater thickness D than that sacrificial thin layer 5 of the arrangement 10, on which this, in particular directly, is arranged or applied. This expediently applies to several, preferably all, sacrificial thin layers 5 of the arrangement 10. It is advantageous if the sacrificial thin layers 5 of the arrangement 10 are formed with increasing thicknesses D in the direction of a side of the arrangement 10 facing away from the functional element 4 or the thicknesses D of the sacrificial thin films 5 form a positive gradient in this direction. The gradient can, for example, be designed to increase linearly.

FIG. 12 shows a schematic representation of the functional component 1 of FIG. 11, with a further arrangement 10 of sacrificial thin layers 5 being additionally arranged between the functional element 4 and the base body 3. An arrangement 10 of sacrificial thin layers 5 is thus advantageously arranged both between the functional element 4 and the cover layer 6 and between the functional element 4 and the base body 3 adjacent to the functional element 4 or applied to the functional element 4 or the base body 3. The further arrangement 10 of sacrificial thin layers 5 can be designed in accordance with the aforementioned arrangement 10 of sacrificial thin layers 5 explained in relation to FIG. 11. It is favorable if the arrangements 10 of sacrificial thin layers 5 are arranged in such a way that they essentially replace an entire interface between the functional element 4 and the cover layer 6 and between the functional element 4 and the base body 3. The functional element is thus, as can be seen in FIG. 9, essentially completely encased by the sacrificial thin layers 5.

Corresponding to an embodiment of the functional component 1 with one or more arrangements 10 of sacrificial thin layers 5 explained in relation to FIG. 11 or FIG be trained.

In an advantageous embodiment variant, it can be provided that the functional element 4 is at least partially, preferably essentially completely, removed from the functional component structure 2 after the covering layer 6 has been applied in order to create a cavity or a hollow space in the functional component structure 2 or the functional component 1 form. Accordingly, it can be favorable if the functional components 1 or functional elements 4 of FIGS. 5 to 12 are each designed in this way. The functional elements 4 shown in FIGS. 5 to 12 then each represent a cavity or a cavity in the functional component 1. In this way, particularly practicable temperature control channels, in particular heating channels and / or cooling channels, can be implemented in the functional component 1. It is expedient if the functional element 4 is designed in such a way that it is or can be at least partially, in particular essentially completely, detachable with a washout agent, in particular water and / or acetone. In this way, the functional element 4 can be washed out with the washout agent in a practicable manner. As can be seen in particular from the functional components 1 shown in FIGS. 5 to 12, removing the functional element 4 from the functional component structure 2 or the functional component 1 results in the formation of a cavity or a cavity, walls which form the cavity or the cavity limit with one or more sacrificial thin layers 5 are formed. In this way, the cavity or the cavity is protected with the sacrificial thin layers 5 when the functional component 1 is in use. In order to ensure a stable structure even after the functional element 4 has been removed, it is advantageous if the sacrificial thin layers 5 are formed with plastic and / or a ceramic material. Depending on the application objective, the thin sacrificial layers 5 can be designed to be heat-insulating or heat-insulating or heat-conducting. This is particularly true when temperature control channels are to be formed with the functional element 4 or the sacrificial thin layers 5 in the aforementioned manner.

In this way, a multi-layer functional component 1 with high usability can be manufactured and used with little effort by protecting sensitive or functionally important parts of the functional component 1 or the functional component structure 2 with one or more sacrificial thin layers 5. By applying sacrificial thin layers 5 to a surface of the functional component structure 2 during the formation of the functional component 1, the surface is protected from a material subsequently arranged on the sacrificial thin layer 5 for the formation of the functional component 1 and from the associated damage energy, usually a high heat input. In that between the functional element 4 and the base body 3 or between the functional element 4 and the cover layer 6, one or more If sacrificial thin layers 5 are arranged, the functional element 4 is protected during the production and during a subsequent application of the functional component 1, so that a functional component 1 with high functional quality and durability can be produced with little effort.

Claims

1. A method for producing a multi-layer functional component (1) which has an integrated functional element (4), for example an electrical conductor track, wherein, to form the functional component (1), the functional element (4) is attached to a base body surface of an, in particular metallic, base body ( 3) is applied, after which at least one cover layer (6) is applied to the base body surface, which covers the functional element (4), characterized in that at least one sacrificial thin layer (5) is arranged in the functional component (1) in order to prevent application material on a surface section of a functional component structure (2) of the functional component (1) to form the functional component (1) a functional component material of the functional component structure (2) with the surface thin layer from damage energy, in particular heat, which is located on a side of the sacrificial thin layer (5) facing away from the surface section when applying gene of the application material is introduced into the functional component structure (2) to protect.

2. The method according to claim 1, characterized in that the at least one sacrificial thin layer (5) between the functional element (4) and the cover layer (6) and / or between the functional element (4) and the base body surface is arranged or applied to with of the sacrificial thin layer (5) to protect the functional element (4) or the base body surface from damage energy, in particular heat supply, during a subsequent application of application material to the functional component structure (2) or its surface section.

3. The method according to claim 1 or 2, characterized in that the sacrificial thin layer (5) is formed with a thickness between 1 pm and 30 pm, preferably between 10 pm and 20 pm.

4. The method according to claim 1 or 3, characterized in that the cover layer (6) is formed with a thickness greater than 30 μm, preferably between 500 μm and 2.5 cm.

5. The method according to any one of claims 1 to 4, characterized in that the application of the application material, in particular the application of the cover layer (6) and / or the application of the functional element (4), with a second application process and the application of the sacrificial thin layer (5 ) is implemented with a first application method, the second application method being more damaging energy intensive or causing greater damage energy than the first application method.

6. The method according to any one of claims 1 to 5, characterized in that when the sacrificial thin layer (5) is applied to a surface area of the functional component structure (2), a surface area material of the surface area is up to a maximum of 0.5 times, in particular 0.3. Times, preferably 0.1 times, a liquidus temperature of the surface area material is heated.

7. The method according to any one of claims 1 to 6, characterized in that the sacrificial thin layer (5) is formed or applied by accelerated particles present in powder form and guided selectively onto a surface of the functional component structure (2), in particular blown, so that the particles form an adhesive sacrificial thin layer (5) when they hit the surface.

8. The method according to claim 7, characterized in that the particles are injected into a flow of a transport gas in order to accelerate the particles and guide them onto the surface of the functional component structure, the transport gas being in a plasma state before the particles are injected into the transport gas Transport gas is transferred to heat the particles.

9. The method according to claim 7 or 8, characterized in that the particles have an average particle size, in particular a volume-equivalent spherical diameter, between 0.1 pm and 25 pm.

10. The method according to any one of claims 1 to 9, characterized in that the sacrificial thin layer (5) is formed or applied with an additive or generative manufacturing process.

11. The method according to any one of claims 1 to 10, characterized in that the application of the application material is carried out using an application process which causes melting of a surface or the surface section of the functional component structure (2) to which the application material is applied.

12. The method according to any one of claims 1 to 11, characterized in that the sacrificial thin layer (5) is arranged in such a way that it essentially forms an entire interface between the functional element (4) and the cover layer (6) and / or between the functional element ( 4) and the base body (3) replaced.

13. The method according to any one of claims 1 to 12, characterized in that the sacrificial thin layer (5) is arranged such that it selectively only substantially the entire interface between the functional element (4) and the cover layer (6) and / or between the Functional element (4) and the base body (3) replaced.

14. The method according to any one of claims 1 to 13, characterized in that the functional element (4) is formed with or as an information conductor and / or energy conductor and / or heat conductor, preferably electrical conductor or light guide.

15. The method according to any one of claims 1 to 14, characterized in that the functional element (4) after application of the cover layer (6) at least partially, preferably substantially completely, is removed from the functional component structure (2) so that a cavity or a A cavity is formed in the functional component (1).

16. The method according to any one of claims 1 to 15, characterized in that the sacrificial thin layer (5) is formed in an electrically insulating manner, in particular with ceramic material and / or with plastic.

17. The method according to any one of claims 1 to 16, characterized in that several sacrificial thin layers (5) are arranged on top of one another, different sacrificial thin layers (5) preferably being formed with different material compositions.

18. The method according to any one of claims 1 to 17, characterized in that the functional element (4) is arranged at least partially, in particular completely, sunk in the base body (3).

19. Functional component (1) with an integrated functional element (4), in particular produced using a method according to one of claims 1 to 18, having an, in particular metallic, base body (3) on which the functional element (4) is applied and a cover layer ( 6), which is applied to the base body (3) so that the functional element (4) is covered by the cover layer (6), characterized in that between the functional element (4) and the cover layer (6) and / or between the functional element (4) and the base body (3) at least one sacrificial thin layer (5) is arranged in order to predefine or prevent an interaction between a functional element material and a base body material or cover layer material in a defined manner.