SEMI-FINISHED PRODUCT AND METHOD FOR PRODUCING A SEMI-FINISHED PRODUCT COMPRISING AT LEAST ONE MICROCOMPONENT

Abstract

A semi-finished product and a method for manufacturing a semi-finished product having at least one micro-component, which method uses a multi-component injection molding process, are disclosed, in which at least one mold chamber of an injection mold is provided with at least one lost part made of a first material, more particularly an injection-molded plastic material, and in another step for producing the micro-component, a second material, which is different from the first material and is elastomer-based, more particularly silicone-based, is injected, as a result of which a firm and form-fitting connection forms between the micro-component and the lost part. In order to be able to achieve advantageous cycle times in a risk-free way, it is proposed for the lost part to be embodied as a macroscopic object holder for the micro-component to permit manipulation of the semi-finished product and for the mold chamber to be provided with this lost part.

Claims

1. A method for manufacturing a semi-finished product having at least one micro-component, the method comprising: using a multi-component injection molding process in which at least one mold chamber of an injection mold is provided with at least one lost part made of a first material, and in another step for producing the at least one micro-component, injecting a second material, which is different from the first material and is elastomer-based, as a result of which a firm and form-fitting connection forms between the at least one micro-component and the at least one lost part, wherein the at least one lost part is embodied as a macroscopic object holder for the at least one micro-component for manipulating the semi-finished product and the at least one mold chamber is provided with the at least one lost part.

2. The method according to claim 1, wherein on the at least one lost part, at least one manipulating surface is embodied on an outside of the semi-finished product, which is left accessible by the at least one micro-component.

3. The method according to claim 1, comprising forming the connection between the at least one micro-component and the at least one lost part during the multi-component injection molding process by injecting the second material through at least one opening in the at least one lost part.

4. The method according to claim 1, wherein the at least one lost part comprises a predetermined breaking point.

5. The method according to claim 4, wherein the predetermined breaking point is embodied as extending toward the form-fitting connection.

6. The method according to claim 1, wherein during the multi-component injection molding process, the at least one lost part forms at least one undercut, more particularly at least one hidden undercut, on the at least one micro-component.

7. The method according to claim 1, comprising removing the at least one lost part from the semi-finished product.

8. The manufacturing method according to claim 7, comprising separating the at least one lost part from the semi-finished product, more particularly by breaking off the at least one lost part from the semi-finished product at a predetermined breaking point in the at least one lost part.

9. A semi-finished product comprising: a lost part; at least one micro-component made of a material that is different from a material of the lost part, wherein the micro-component material is elastomer-based; and a firm and form-fitting connection between the at least one micro-component and the lost part, wherein the lost part is embodied as a macroscopic object holder for the at least one micro-component for manipulating the semi-finished product.

10. The semi-finished product according to claim 9, wherein the lost part forms at least one manipulating surface on an outside of the semi-finished product which is left accessible by the at least one micro-component.

11. The semi-finished product according to claim 9, wherein the lost part forms at least one positioning aid on an outside of the semi-finished product, which is left accessible by the at least one micro-component.

12. The semi-finished product according to claim 9, wherein the lost part has an opening through which the at least one micro-component protrudes to form the connection.

13. The semi-finished product according to claim 9, wherein the lost part has a predetermined breaking point for destroying the connection between the at least one micro-component and the lost part and more particularly, the predetermined breaking point extends toward the form-fitting connection.

14. The semi-finished product according to claim 9, wherein the lost part, which is comprised of a thermoplastic, is embodied as plate-shaped.

15. The semi-finished product according to claim 9, wherein the lost part has at least one overhang that forms an undercut, more particularly a hidden undercut, on the at least one micro-component.

16. The method according to claim 1, wherein the first material is an injection-molded plastic material.

17. The method according to claim 1, wherein the second material is silicone-based.

18. The method according to claim 4, wherein the predetermined breaking point is embodied as extending toward an opening in the at least one lost part through which the second material is injected during the multi-component injection molding process, and more particularly, is embodied as ending before the opening.

19. The semi-finished product according to claim 9, wherein the micro-component material is silicone-based.

20. The semi-finished product according to claim 13, wherein the predetermined breaking point extends toward an opening in the lost part through which the at least one micro-component protrudes to form the connection, and more particularly, the predetermined breaking point ends before the opening.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The subject of the invention is shown by way of example in the drawings. In the drawings:

[0026] FIG. 1 shows a top view of a semi-finished product with a micro-component,

[0027] FIG. 2 shows a sectional view according to the line 11-11 in FIG. 1, and

[0028] FIG. 3 shows a bottom view of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] For example, FIGS. 1 to 3 show the semi-finished product 1 according to the invention composed of a lost part 2 and a micro-component 3. The lost part 2 and the micro-component 3 of are made different materialsthe lost part 2 consists of a thermoplastic and the micro-component 3 consists of silicone. Other materials are conceivable. The lost part 2 and the micro-component 3 are firmly connected to each other by a form-fitting connection 4. This connection 4 is particularly visible in FIG. 2. Preferably, this connection 4 is free of material bonding due to chemical interaction. The connection 4 is produced by using a multi-component injection molding process, which is known and not depicted in detail, in that the lost part 2 is provided in a mold chamber of an injection mold and then an elastomer-based material, namely silicone for example, is injected in order to thus produce the micro-component 3. By removing, for example destroying, the lost part 2, it is possible to eliminate this firm, form-fitting connection 4, thus separating the micro-component 3 from the semi-finished product 1. In general, it should be noted that the firm and form-fitting connection 4 can be permanent or non-detachable.

[0030] By contrast with known semi-finished products, with micro-components, the lost part 2 according to the invention serves not only to form contours on the micro-component 3, but also assumes the function of a macroscopic object holder 5 for the micro-component 3. The selection of a macroscopic object holder 5 also simplifies an automated manipulation of the micro-component 3in addition, its risk of being damaged by manipulators that are not shown is also particularly reduced. The latter is especially also due to the fact that the lost part 2 forms a manipulation surface 7 for the manipulator on the outside 6 of the semi-finished product 1, which surface is left accessible by the micro-component 3. To be precise, a manipulator for manipulating the semi-finished product 1 can avoid contact surfaces on the micro-component 3; the lost part 2 can be used to supply the carried micro-component 3 and the semi-finished product 1 to manipulation tasks, positioning tasks, and/or measuring tasks. Among other things, the manipulator holds the micro-component 3 in a stress-free way as the latter is being positioned.

[0031] As is apparent from FIGS. 1 to 3, this manipulation surface 7 on the outside 6 of the semi-finished product 1 is significantly larger in area than the micro-component 3. Such a manipulation surface 7 can be manufactured in a simple way in terms of the process in that during the multi-component injection molding process, the lost part 2 remains correspondingly free of the second material. This can take place, for example, through the shape of the mold chamber of the injection mold and/or also upon ejection of the micro-component 3 from the injection mold by means of a tearing-off, a laser cutting, or another cutting method. In general, it should be noted that this manipulation surface 7 can be formed on any side of the lost part 2 that remains accessible by the micro-component 3 on the outside of the semi-finished product 1. This manipulation surface 7 can, for example, be used by picker arms, suction holders, etc., in order to manipulate the semi-finished product 1 for other steps.

[0032] The multi-component injection molding process according to the invention that is used to manufacture this micro-component can also be understood as a multi-component micro-injection molding process.

[0033] To this end, it should be noted in general that an injection molding of micro-components or micro-injection molding can basically be explained by means of the procedures used in the manufacture of macro-components. The differences primarily lie in the weight of the components. It is generally noted that the weight of micro-components can lie in the range of a few mg and preferably fewer than 10 mg, which can thus result in dimensions beginning in the m range down to 0.1 m. By contrast with this, the component weight and thus the size of macro-components is quite clearly larger than the m range.

[0034] The removal of the lost part 2 or object holder is considerably easier if the lost part 2 has a predetermined breaking point 8, which is depicted in FIG. 3. This predetermined breaking point 8 also features the fact that it extends from the opposite ends 15 of the lost part 2 or semi-finished product 1 to an opening 9 in the lost part 2, which opening 9 contributes to the form-fitting connection 4, with the micro-component 3 or the neck 10 thereof protruding through it. If the lost part 2 breaks along this predetermined breaking point 8, this destroys the form-fitting connection 4 between the lost part 2 and the micro-component 3 and releases the micro-component 3 without damage. As is also apparent from FIG. 3, the predetermined breaking point 8 in the lost part 2 ends, tapering to a point before the opening in order to avoid reducing the strength of the semi-finished product 1 in the vicinity of the enclosed neck 10 of the micro-component 3, but nevertheless produce a reliable breaking line. It is also conceivable for the micro-component 3 to be pressed out from the lost part 2 or the object holder, which is quite possible with silicone components of this kind.

[0035] As can be inferred from FIG. 2, the semi-finished product 1 is flat and by extension plate-shaped. Adjustable feet 11 are injection molded onto the semi-finished product 1 in order to be able to cut the semi-finished product 1 off from the micro-component 3 in a non-damaging way. Foot recesses 12 on the top side of the semi-finished product enhance the stackability of the semi-finished products 1.

[0036] Due to the reproducible manipulation of the semi-finished product 1, the micro-component 3 is particularly suitable for use in electrical engineering in that the semi-finished product is provided with a passive RFID transponder 13. According to FIG. 2, this RFID transponder 13 is provided in a recess 14 of the micro-component 3. It is also conceivable to provide a medicinal substance 13 in this recess. All of this is reproducibly possible in that the manipulation surfaces 7 on the lost part 2 enable an exact positioning of the micro-component 3 by a manipulator.

[0037] In addition, the micro-component 3 on the one hand can be held in a particularly secure fashion by the lost part 2 and on the other hand, can be steadily held by a hand tool if multiple mounting recesses are provided on the micro-component 3. One of these mounting recesses is provided in the micro-component 3 in a simple way in terms of the process in that during the multi-component injection molding process, an overhang 16 on the lost part 2 forms a hidden undercut 17hidden in that only after a removal of a part (for example the right half of the lost part 2 shown in FIG. 2) does this mounting recess become accessible and can thus be revealed. It therefore also becomes possible, after a partial removal of the lost part 2, to already hold and grasp the micro-component 3 before the lost part 2 is completely removed. This makes the manipulation of the micro-component 3 user-friendly. As shown with dashed lines in FIG. 2, it is also conceivable for two or more overhangs 16 to be provided on the lost part 2 in order, for example, to thus improve the cohesion of the semi-finished product 1.

[0038] As is also indicated particularly in FIG. 1, on the top side of the semi-finished product 1, namely on the lost part 2, two groove-shaped opposing recesses are provided, which serve as a positioning aid 18. The semi-finished product 1 can thus be oriented in a way that is easy for the manipulator by means of centering projections, not shown in detail, which can engage in this positioning aid 18. It is thus possible to further facilitate the manipulation of the semi-finished product 1.

[0039] In general, it should also be noted that it is possible to synthesize an elastomer base that is based on NBR (nitrile rubber), HNBR (hydrogenated nitrile rubber), FPM (fluoroelastomer), EPDM (ethylene propylene rubber with a third component), ECO (epichlorohydrin rubber), TPE (thermoplastic elastomers) with or without a release agent, HTV silicone (high temperature vulcanized silicone rubber), or also silicone in general.