CONNECTING ELEMENT, COMPONENT OF A COMPOSITE MATERIAL AND METHOD FOR PRODUCING A COMPONENT FROM A COMPOSITE MATERIAL

Abstract

A connecting element is configured to position a stabilizing member during the production of a component from a composite material, the connecting element having openings into which a melt composition in a molten state can flow, and the connecting element having at least one positioning device configured to position the stabilizing member on the connecting element. A component of a composite material has a cohesive, hardened melt composition, the connecting element described above, and at least one stabilizing member, the connecting element and the at least one stabilizing member being embedded in the melt composition, the melt composition reaching into the connecting element through the openings of the connecting element, and the at least one stabilizing member being positioned on the at least one positioning device of the connecting element.

Claims

1. A connecting element configured to position a stabilizing member during production of a component from a composite material, the connecting element having openings into which a melt composition in a molten state can flow, and the connecting element having at least one positioning device configured to position the stabilizing member on the connecting element.

2. The connecting element according to claim 1, further comprising channels adjoining the openings, wherein the channels run in the connecting element.

3. The connecting element according to claim 2, wherein the channels form a grid structure.

4. The connecting element according to claim 1, wherein the at least one positioning device is formed by a passage in the connecting element through which the stabilizing member is passed.

5. The connecting element according to claim 4, wherein the passage is formed between an opening portion of the connecting element and a wall portion of the connecting element, the openings of the connecting element being arranged in the opening portion and the wall portion not having any openings.

6. The connecting element according to claim 1, wherein the connecting element has a plurality of positioning devices which form passages in the connecting element through which the stabilizing member is passed, the passages forming slits which are aligned parallel to one another on a surface of the connecting element.

7. The connecting element according to claim 6, wherein the slits have a matching width and are arranged in line with one another.

8. The connecting element according to claim 1, wherein the at least one positioning device is formed by a projection around which the stabilizing member is passed or onto which the stabilizing member is pushed.

9. The connecting element according to claim 8, wherein the projection has a first grid structure, a portion of the connecting element from which the projection protrudes having a second grid structure, and the first grid structure being different than the second grid structure.

10. The connecting element according to claim 1, wherein the connecting element has at least one protruding retaining element extending from a surface of the connecting element.

11. A component of a composite material comprising: a connecting element; and at least one stabilizing member, wherein the connecting element is configured to position the at least one stabilizing member during production of the component, the connecting element having openings into which a melt composition in a molten state can flow, and the connecting element having at least one positioning device configured to position the at least one stabilizing member on the connecting element, and wherein the connecting element and the at least one stabilizing member are embedded in the melt composition, the melt composition reaching into the connecting element through the openings of the connecting element, and the at least one stabilizing member being positioned on the at least positioning device of the connecting element.

12. The component according to claim 11, wherein the melt composition is an injection molding material and the at least one stabilizing member is a fiber tape.

13. The component according to claim 11, further comprising channels adjoining the openings, wherein the channels run in the connecting element, and wherein the channels form a grid structure.

14. The component according to claim 11, wherein the connecting element has a plurality of positioning devices which form passages in the connecting element through which the at least one stabilizing member is passed, the passages forming slits are aligned parallel to one another on a surface of the connecting element.

15. The component according to claim 14, wherein the slits have a matching width and are arranged in line with one another.

16. The component according to claim 11, wherein the connecting element has at least one protruding retaining element extending from a surface of the connecting element.

17. A method for producing a component from a composite material, the method comprising: providing at least one connecting element, the at least one connecting element being configured to position a stabilizing member during production of the component from a composite material, the at least one connecting element having openings into which a melt composition in a molten state can flow, and the at least one connecting element having at least one positioning device configured to position the stabilizing member on the connecting element; providing a positioning arrangement comprising the connecting element and the stabilizing member by positioning the stabilizing member on the positioning device of the connecting element; and fixing the positioning arrangement by a melt composition by melting the melt composition, such that the melt composition flows into the openings of the connecting element and produces a materially bonded and/or form-fitting connection to the connecting element and the stabilizing member.

18. The method according to claim 17, wherein a 3D printing process is used to provide the at least one connecting element, in which at least one portion of the connecting element in which the openings are arranged is produced by the 3D printing process.

19. The method according to claim 17, wherein the melt composition is an injection molding material and the stabilizing member is a fiber tape, and wherein the fixing of the positioning arrangement further comprises: melting the injection molding material; and overmolding the positioning arrangement with the injection molding material in an injection molding tool.

20. The method according to claim 19, wherein a 3D printing process is used to provide the at least one connecting element in which at least one portion of the connecting element in which the openings are arranged is produced by the 3D printing process.

Description

DRAWINGS

[0038] In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:

[0039] FIG. 1 shows a schematic illustration of a connecting element with a projection according to the present disclosure;

[0040] FIG. 2 shows a schematic illustration of a connecting element with a plurality of projections according to the present disclosure;

[0041] FIG. 3 shows a cross-sectional view of a connecting element with a plurality of passages according to the present disclosure;

[0042] FIG. 4 shows a plan view of a connecting element with a plurality of passages according to the present disclosure;

[0043] FIG. 5 shows a schematic illustration of a connecting element according to the present disclosure, in which a passage is formed between an opening portion and a wall portion of the connecting element;

[0044] FIG. 6 shows a schematic illustration of a connecting element with a plurality of retaining elements according to the present disclosure and

[0045] FIG. 7 shows a cross-sectional view of a component of a composite material of the present disclosure, the component comprising a connecting element, a fiber tape, and an injection molding material.

[0046] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

[0047] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0048] FIG. 1 shows a schematic illustration of a connecting element 1 with a projection 2. The connecting element 1 is manufactured from a plastics material. The connecting element 1 has a plurality of openings 3, adjoining which are channels which run inside the connecting element 1 and form a grid structure 4. An injection molding material can be injection molded around the connecting element 1 and penetrate through the openings 3 in the channels, such that a strong form-fitting and/or materially bonded connection is produced between the injection molding material and the connecting element 1. In that case, the injection molding material serves as a melt composition. The projection 2 forms a positioning device of the connecting element 1. It is possible, for example, for a fiber tape to be passed around the projection 2, which tape serves as a stabilizing member for the component. Together with the fiber tape and the injection molding material, the connecting element 1 may form a component in which the connecting element 1 produces a reliable connection between the fiber tape and the injection molding material.

[0049] FIG. 2 shows a schematic illustration of a connecting element 1 with a plurality of projections 2. Portions of the connecting element 1 which form the projections 2 have a first grid structure 5. A portion of the connecting element 1 from which the projections 2 protrude has a second grid structure 6. The first grid structure 5 differs from the second grid structure 6 in terms of the size of openings 3 in the grid structures 5 and 6 and in terms of the orientation of said openings. In this way, the connecting element 1 is adapted specifically to requirements on connecting forces between the connecting element 1 and an injection molding material, with which the connecting element 1 can be overmolded.

[0050] FIG. 3 shows a cross-sectional view of a connecting element 1 with a plurality of passages 7. The passages form positioning devices of the connecting element 1. The connecting element 1 also has a grid structure 4. A fiber tape 8 is passed through the passages 7 and positioned on the connecting element 1 in this way. The fiber tape 8 runs in an alternating manner along a top side 9 and a bottom side 10 of the connecting element 1. Such a connecting element 1 can be produced by a 3D printing process. Here, both the grid structure 4 and the passages 7 can be laid in the connecting element 1 already during the manufacture. It is, however, also possible for the passages 7 to be introduced into the connecting element 1 only subsequently, for example by a material-removing process.

[0051] FIG. 4 shows a plan view of a connecting element 1 with a plurality of passages 7. The connecting element 1 has a circular cross section and is provided with a grid structure 4. A fiber tape 8 is passed through the passages 7 and runs in an alternating manner along a top side 9 and a bottom side, which is not visible, of the connecting element 1. The passages 7 form slits 11 on the top side 9 of the connecting element 1. The slits 11 have a matching width and are arranged in line with one another. If an injection molding material is injection molded around this connecting element 1, the connecting element 1 together with the injection molding material and the fiber tape 8 forms a component of a composite material, which can withstand large forces in the direction of the arrow 12. The arrangement of the fiber tapes 8 in the passages 7 produces a strong anchoring because the injection molding material can also penetrate into the passages 7, where it encloses the fiber tape 8 and thus fixes it to the connecting element 1.

[0052] FIG. 5 shows a schematic illustration of a connecting element 1, in which a passage 7 is formed between an opening portion 13 and a wall portion 14 of the connecting element 1. The connecting element 1 has a grid structure 4, which is located exclusively in the opening portion 13. The connecting element 1 can be produced completely by a 3D printing process, but it is also possible for the wall portion 14 to be an additional element which has subsequently been placed onto the opening portion 13. A fiber tape 8 is passed through the passage 7 of the connecting element 1. The opening portion 13 has a circular cross section. The connecting element 1 positions the fiber tape 8 when an injection molding material is injection molded around it. Since the injection molding material can penetrate into openings 3 in the opening portion 13, a connection between the injection molding material, the connecting element 1, and the fiber tape 8 that is able to bear high loads is formed.

[0053] FIG. 6 shows a schematic illustration of a connecting element 1 with a plurality of retaining elements 15. As described above, an injection molding material can penetrate into the connecting element 1 through the openings 3 of the connecting element 1 during an injection molding operation. As soon as the injection molding material has hardened, a materially bonded and/or form-fitting connection exists between the injection molding material and the connecting element 1. It may, however, also be desired to anchor the connecting element 1 additionally in the injection molding material, in particular when tensile forces are exerted on the fiber tape 8. For this purpose, protruding retaining elements 15 are arranged on the connecting element 1. The protruding retaining elements 15 serve as anchors in the hardened injection molding material. If a force is exerted on the fiber tape 8 in the direction of the arrow 12, the fiber tape 8 transmits this force onto the connecting element 1, which in turn is anchored securely in the injection molding material by the retaining element.

[0054] FIG. 7 shows a cross-sectional view of a component 16 of a composite material, the component comprising a connecting element 1, a fiber tape 8 and an injection molding material 17. The connecting element 1 used was described above with reference to FIG. 6. The fiber tape 8 is passed through a passage 7 of the connecting element 1. The injection molding material 17 encloses the fiber tape 8 and the connecting element 1. The component 16 is resistant to tensile forces in the direction of the arrow 12. The connecting element 1 anchors the fiber tape securely in the injection molding material 17. In addition, during the production of the component 16, in particular during the overmolding of the fiber tape with the injection molding material 17, the connecting element 1 provides a desired positioning of the fiber tape 8 within the component 16.

[0055] Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability.

[0056] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”

[0057] The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.