ADDITIVE PRODUCTION OF A THREE-DIMENSIONAL COMPONENT COMPRISING AN ENVELOPING ELEMENT AND A FILLER MATERIAL

Abstract

The invention relates to a method for the production of a component, comprising the steps of: creating at least one portion of an enveloping element (10) of the component by means of an additive method, and introducing a filler material (20), which is in particular foamable or at least partially foamed, into the portion of the enveloping element (10).

Claims

1. A method for the production of a component, comprising the steps of: creating at least one portion of an enveloping element of the component by an additive method; and introducing a filler material into the portion of the enveloping element.

2. The method according to claim 1, wherein the additive method comprises a fused filament fabrication method using a thermoplastic material.

3. The method according to claim 1, wherein the filler material is wood foam, aluminium foam, plastic foam or a polyurethane foam material.

4. The method according to claim 1, wherein such a quantity of filler material is introduced into the portion of the enveloping element that the filler material emerges from the portion of the enveloping element.

5. The method according to claim 1, further comprising the step of: creating at least one layer on the filler material using an additive method for covering the filler material at least in sections.

6. The method according to claim 1, further comprising the step of: creating at least one further portion of the enveloping element by an additive method.

7. The method according to claim 1, wherein foaming of the filler material takes place prior to, during or after introduction of the filler material.

8. The method according to claim 1, wherein the steps of creating at least one portion of the enveloping element and introducing a filler material in the portion of the enveloping element are repeated several times.

9. The method according to claim 1, wherein the enveloping element is provided and/or printed with a coating or decorative element.

10. The method according to claim 1, wherein a supporting structure is created with the at least one portion or the at least one further portion of the enveloping element to support the component to be created.

11. The method according to claim 1, wherein a recess is made in the filler material introduced into the portion of the enveloping element using an erosive machining method.

12. The method according to claim 11, wherein a pourable or paste-like material is introduced into the recess.

13. A device for the production of a component, comprising: a first device for creating at least one portion of an enveloping element of the component by an additive method; and a second device for introducing a filler material into the portion of the enveloping element.

14. The device according to claim 13, wherein the first device and the second device are attached to a carrier.

15. The device according to claim 13, wherein the first device comprises an extruder that is set up to heat and discharge a filament-like material.

16. The device according to claim 13, wherein, the device also comprises a machining unit.

17. A component comprising: at least one enveloping element that forms at least a portion of an outer surface of the product, and a filler material, the at least one enveloping element being manufactured by an additive method.

18. The method according to claim 1, wherein the filler material is foamable or at least partially foamed.

19. The method according to claim 3, wherein the polyurethane foam material is a 2-component polyurethane foam material.

20. The method according to claim 4, wherein after introduction of the filler material, an exposed area of the filler material is machined with an erosive, chip-generating, method, to produce an even surface.

21. The method according to claim 5, wherein the additive method for creating the at least one layer on the filler material comprises a fused filament fabrication method.

22. The method according to claim 6, wherein the additive method for creating the at least one further portion comprises a fused filament fabrication method, and wherein the at least one further portion of the enveloping element is subsequently filled with a filler material.

23. The method according to claim 7, wherein foaming of the filler material comprises adding a blowing gas such as nitrogen or carbon dioxide or by mixing in a foaming agent.

24. The method according to claim 11, wherein the erosive machining method corresponds to using a drill or a milling cutter.

25. The method according to claim 12, wherein the pourable or paste-like material is a plastic material.

26. The device according to claim 13, wherein the first device is a printing device.

27. The device according to claim 13, wherein the filler material is a foamable or at least partially foamed filler material.

28. The device according to claim 14, wherein the carrier is a cantilever, portal or articulated arm robot, and wherein the first device and the second device are attached to a carriage that is movable along the carrier.

29. The device according to claim 15, wherein the filament-like material is a thermoplastic material.

30. The device according to claim 16, wherein the erosive machining is chip-generating machining, and wherein the machining unit is a milling unit, drilling unit or grinding unit.

31. The device according to claim 30, wherein the machining unit is attached together with the first device and/or the second device to a carrier, wherein the carrier is a cantilever, portal or articulated arm robot, and wherein the machining unit is attached together with the first device and/or the second device to a carriage that is movable along the carrier.

32. The component according to claim 17, wherein the component is a piece of furniture, the piece of furniture being a kitchen worktop, a front panel of a piece of furniture, a leaf, a flooring element or a counter.

33. The component according to claim 17, wherein the filler material is arranged within and fills at least one enveloping element, and wherein the additive method is a fused filament fabrication method.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0049] FIG. 1 shows a first embodiment of the sequence of a method according to the invention

[0050] FIG. 2 shows a second embodiment of the sequence of a method according to the invention

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0051] Exemplary sequences of a method according to the invention are described below based on the enclosed figures. Other modifications of certain steps of the method cited in this context can each also be combined individually to create new embodiments.

[0052] FIG. 1 shows a first embodiment of the sequence of a method according to the invention.

[0053] First of all, as part of the method, an enveloping element 10 is created (printed) using a fused filament fabrication method in a first method step S1. To this end, the corresponding material, in particular a thermoplastic material, is melted in an extruder and pressed through a nozzle of printing device 1.

[0054] Once the enveloping element 10 has been produced with a side open upwards in a vertical direction in method step S1, a foam material 20 by way of an exemplary filler material is introduced into the enveloping element 10 in a subsequent method step S2 using a foam discharging device 2 (foam nozzle). The enveloping element 10 is essentially completely filled.

[0055] The aforementioned foam material 20 may be, for example, a reactive foam such as a PU foam, which is, so to speak, injected into the enveloping element 10 and expands therein. As the foam material 20 hardens, it also connects to the inside of the enveloping element 10.

[0056] In a subsequent method step S3, the foam material 20 that is present in the area of the open side of the enveloping element 10 and is uneven or protruding is removed. In this context, a milling unit 3 is used to remove the protruding foam material 20 by milling, and an even surface of the foam material 20 is thus achieved. The milling unit 3 can be a 3-axis milling unit, a 4-axis milling unit or a 5-axis milling unit.

[0057] On completion of milling, there is an intermediate product in method step S4, wherein the side areas and the underside of the intermediate product are formed by the enveloping element 10 and the top side of the intermediate product is largely formed by the smoothed and milled foam material 20. Method step S4 may comprise the cleaning of the intermediate product.

[0058] In a further method step S5, a portion of the milled foam material is now printed with the fused filament fabrication method using the printing device 1. In the present exemplary embodiment, an even surface is created section by section as part of the enveloping element 10.

[0059] In addition, another outer contour is printed in a method step S6, thereby in effect expanding the enveloping element 10. The outer contour created in the method step defines a cavity. Once the outer area of the expanded enveloping element 10 has been created, the resulting cavity is filled with foam (method step S7). The opening area of the expanded enveloping element 10 is also milled and any protruding parts of the foam material are removed as part of this process (method step S8).

[0060] The portion of foam material still exposed is subsequently printed with the printing device as part of the method of the invention and the enveloping element is thus closed (method steps S9, S10). Cleaning can take place after method step 8.

[0061] As part of the embodiment described here, a production method for creating a relatively simple component has been described. It is clear that complex components can also be manufactured using the procedure described. In particular, it is possible to repeat the method steps as many times as required to expand the component. This particularly applies to method steps S6 to S8.

[0062] In the method described, the component density can be controlled based on the foaming behaviour and porosity of the foam material 20 used. Depending on the foam system used, the porosity can be adjusted with a high degree of precision. This particularly applies to 2-component PU foams, based on the mixing ratio of the two components, for example.

[0063] The present method can be used, for example, to create pieces of furniture, such as kitchen worktops, table tops, front panels of furniture, leaves, floorings, or similar. In particular, the method is suitable for components of large volume.

[0064] Furthermore, it is also possible to supplement the components manufactured in this way with simply structured components, for example by connecting other elements using an adhesive method. Purely as an example, a component manufactured according to the method shown in FIG. 1 above could be produced on a plate-shaped workpiece to provide a cost-effective method for manufacturing complex components.

[0065] Although the foam material is introduced into the enveloping element 10 vertically from above as part of the method described with reference to FIG. 1, it is also possible to introduce the foam material into the enveloping element through an opening on the side.

[0066] Furthermore, it is possible to also print a filler structure within the enveloping element 10 if, for example, higher strength requirements are set, or if the enveloping element 10 is designed with relatively thin walls.

[0067] Another embodiment of the present invention is described below in connection with FIG. 2.

[0068] First of all, a portion of an enveloping element 10 is produced in a first method step A1. Method step A1 could correspond to method step S1 according to FIG. 1.

[0069] The foam material 20 is subsequently introduced into the enveloping element 10 in a method step (not shown in FIG. 2) and an even surface is created using a milling tool. The enveloping element 10 with the foam material 20 is now present in the form shown in method step A2.

[0070] A ring-shaped portion 25 is now removed from the area of the foam material 20 using an erosive machining method. A drill or milling tool particularly suited to the task is used for this, for example. A pin-like body 26 made from the foam material 20 (method step A3) remains in the centre of the ring-shaped portion 25.

[0071] Subsequently, the ring-shaped portion 25 is filled with a plastic material 30 (method step A4). This plastic material 30 may be introduced into the ring-shaped portion 25 in a liquid or paste-like form, for example.

[0072] In a further method step A5, the pin-like body 26 is now removed from the foam material 20 using a drill/milling cutter. The plastic material 30 thus forms a body through which a pin 40 can be inserted in a further method step A6.

[0073] The pin 40 should only be regarded as an example here. A shaft could alternatively also be inserted into the plastic body 30. A plastic material with the properties of a friction bearing can be used here.

[0074] In addition, a ring-shaped portion 25 that is filled by the plastic material 30 is shown in the embodiment described here. The ring-shaped portion 25 could also be designed as an angular portion, oval portion etc., with or without a centre opening.

[0075] The alternatives cited above can also be implemented as part of the second embodiment. For example, the design of the enveloping element 10 can be as complex as required once the enveloping element 10 has been manufactured using an additive method.

[0076] Even if a foam material that is foamed before, during or after introduction into the portion of the enveloping element 10 is described as a filler material as part of the present embodiment, other filler materials are also conceivable within the context of the invention.