ADDITIVELY MANUFACTURED COMPONENT OUT OF METAL OR PLASTIC MATERIAL WITH A STANDARD THREAD

Abstract

A component bond out of an additively manufactured component out of metal or plastic material having an inner receiving space that is open on at least one side on a component opening, which is accessible from a component side and is configured fungiform in an axial cross section. The receiving space includes at least one widened molding section facing the component opening and at least one cylinder shaped support section facing away from the component opening, wherein a blind rivet nut or a blind rivet bolt are fastened in the receiving space by a compression bead of the blind rivet nut or of the blind rivet bolt extending into the molding section.

Claims

1. An additively manufactured component out of metal or plastic material having an inner receiving space that is open on at least one side at a component opening, which is accessible from a component side and is configured fungiform in an axial cross section, wherein the receiving space includes at least one widened molding section facing the component opening and at least one cylinder shaped support section facing away from the component opening.

2. The additively manufactured component according to claim 1, in which a diameter D.sub.1 of the molding section is larger than a diameter D.sub.2 of the support section.

3. The additively manufactured component according to claim 1, in which the support section includes a circumferential inner wall which is circumferentially structured by a diameter variation of the support section.

4. The additively manufactured component according to claim 1, in which the molding section comprises a circumferential inner wall which is circumferentially structured by a diameter variation of the molding section.

5. The additively manufactured component according to claim 1, in which a diameter D.sub.1 of the molding section has a relation to a diameter D.sub.2 of the support section according to
0.6≤D.sub.2/D.sub.1≤0.95.

6. The additively manufactured component according to claim 1, in which the molding section has an axial extension h.sub.E in a range 0.5 mm≤h.sub.E≤10 mm.

7. The additively manufactured component according to claim 1, in which a circumferential retaining collar which projects radially to the inside is arranged between the component opening and the molding section, the collar serving as an axial clamping portion with an axial thickness h.sub.K in a range from 0.5 mm≤h.sub.K≤5 mm.

8. The additively manufactured component according to claim 1, in which an axial step is arranged between the component surface and the molding section.

9. The additively manufactured component according to claim 8, in which the cylinder-like support section comprises an inner thread.

10. A component bond consisting of an additively manufactured component according to claim 1 and a blind rivet nut or a blind rivet bolt, each being fastened in the receiving space, with a compression bead of the blind rivet nut or of the blind rivet bolt extending into the widened molding section.

11. A component bond consisting of an additively manufactured component according to claim 9 and a thread sleeve with a radially outer fastening thread and a radially inner true-to-gauge thread, the thread sleeve being fastened in the receiving space, wherein a compression bead of the thread sleeve extends into the widened molding section.

12. The component bond according to claim 11, wherein an end collar of the thread sleeve is arranged in the axial step of the component and forms a form-fit connection with the component.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] In the following, the present disclosure is described in detail with reference to the drawings. In the drawings, the same reference signs denote the same components and/or elements. They show:

[0049] FIG. 1 an embodiment of a blind rivet nut in a partial sectional view,

[0050] FIG. 2 an embodiment of an additively manufactured component with a blind rivet nut fastened in it,

[0051] FIG. 3 a perspective view of an embodiment of a blind rivet bolt,

[0052] FIG. 4 an embodiment of an additively manufactured component with a blind rivet bolt fastened in it,

[0053] FIG. 5 a partial sectional view of an embodiment of a thread sleeve with compression section,

[0054] FIG. 6 an embodiment of a component bond out of an additively manufactured component with a thread sleeve fastened in it having a compression portion,

[0055] FIG. 7 a perspective partial sectional view of an embodiment of an additively manufactured component,

[0056] FIG. 8 a partial sectional view of an enlarged section from an additively manufactured component,

[0057] FIG. 9 a further enlarged section of a configuration of the additively manufactured component,

[0058] FIG. 10 a perspective sectional view of a further configuration of the additively manufactured component,

[0059] FIG. 11 an overview of configurations of a circumferential contour of the molding section and/or the support section, each in a schematic radial sectional view,

[0060] FIG. 12 an embodiment of a component bond consisting of an additively manufactured component and a thread sleeve with rivet base in a sectional view,

[0061] FIG. 13 a flow chart of an embodiment of an additive manufacturing method of a component, and

[0062] FIG. 14 a flow chart of an embodiment of a manufacturing method of an additively manufactured component with a true-to-gauge thread, which may be a standard thread.

DETAILED DESCRIPTION

[0063] The present disclosure provides a component that is manufactured with an additive manufacturing method, the component being equipped with a loadable and true-to-gauge thread, which may be a standard thread. Additive manufacturing methods use metal or plastic powder or granules in order to constrict the component in layers. The basis for that is a computer-generated three-dimensional model of the component which is converted into a layer model before the manufacturing. Such methods for different materials are known in the state of the art. Further embodiments of the additively manufactured components 10; 30; 50 are schematically shown in FIGS. 2, 4, 6, 7-10 and 12.

[0064] In order to equip the additively manufactured components 10; 30; 50 with a true-to-gauge inner thread 25, which may be a standard thread, a thread element 20; 22; 40; 60 is fastened in the respective additively manufactured component 10; 30; 50, as is shown in FIGS. 2, 4, 6, 12.

[0065] The connection of additively manufactured component 10; 30; 50 and the thread element 20; 22; 40; 60 forms a component bond A; B; C; D.

[0066] In the first component bond A, a blind rivet nut 20 (see FIG. 1) which is known in the state of the art is fastened in the additively manufactured component 10 of plastic material or metal. The blind rivet nut 20 comprises a hollow cylindrical like shaft 24 with an inner thread portion 25 and a compression portion 26. The compression portion 26 is arranged adjacent to a circumferential collar 28, which projects radially to the outside with respect to the compression portion 26.

[0067] The radial outer counter of the hollow cylindrical shaft 24 is configured round or angular or generally non-round. A non-round contour may have the advantage that a rotation inhibition of the blind rivet nut 20 may be supported in the component 10.

[0068] A known blind rivet bolt 22 is constructed in a similar way as the blind rivet nut 20 (see FIG. 3). The former also includes the hollow cylindrical like shaft 24 with the compression portion 26 and the extensively circumferential collar 28. A thread bolt 29 is fastened in the thread portion 25, which projects beyond the circumferential collar 28 and comprises an outer thread.

[0069] For receiving and fastening the blind rivet nut 20 and the blind rivet bolt 22, the component 10 includes an inner receiving space 12. The receiving space 12 is accessible from at least one side via a component opening 11. The blind rivet nut 20 or the blind rivet bolt 22 are plugged into the receiving space 12 through the component opening 11. The receiving space 12 may be provided with both sides being open in axial direction.

[0070] The receiving space 12 is divided into a widened molding section 14 facing the component opening 11. A cylinder like support section 16 is provided which faces away from the component opening 11. The receiving space 12 is configured fungiform in an axial cross-section due to its construction out of beadlike molding section 14 and cylinder like support section 16, as can be recognized in FIGS. 2, 4, 7-10. Accordingly, an inner diameter of the molding section 14 is configured lager than the support section 16.

[0071] Due to the differences in diameter between the molding section 14 and the support section 16, the forming of an undercut of the compression portion 26 in axial direction of the blind rivet nut 20 and the blind rivet bolt 22 may be supported. This undercut of the compression portion 26 may secure the blind rivet nut 20 or the blind rivet bolt 22 within the component 10.

[0072] In order to establish the component bond A; B, the component 10; 20; 30; 50 is first of all manufactured with the additive manufacturing method. The basis for the manufacturing is the provision of the component 10; 20; 30; 50 as a three-dimensional component drawing (step S1).

[0073] Subsequently, the three-dimensional component drawing is converted into a layer model in order to be able to additively manufacture the component 10; 20; 30; 50 out of plastic material or metal in layers in a computer-controlled manner on this basis (step S2).

[0074] As soon as the layer model of the component 10; 20; 30; 50 has been manufactured in a computer-based manner, the additive manufacturing of the component 10; 20; 30; 50 takes place (step S3).

[0075] As during the additive manufacturing of the components 10; 20; 30; 50, a thread that is true to gauge, which may be a standard thread, can only be manufactured with great effort or cannot be manufactured at all, the component 10; 20; 30; 50 may be connected with the thread element 20; 22; 40; 60 in a not detachable manner which may be after its additive manufacturing. The thread elements 20; 22; 40; 60 include a true-to-gauge thread 25, which may be a standard thread.

[0076] In order to allow a screw to be rotated into the thread 25 accurately, both the thread dimensions of the screw as well as those of the thread 25 must offer sufficient play for the screwing process. This play is guaranteed by the accuracy to gauge. The same applies analogously to the blind rivet bolt 22 with outer thread.

[0077] Once the additively manufactured component 10; 30; 50 and the thread element 20; 22; 40; 60 have been provided in step H1, the thread element 20; 22; 40; 60 is inserted into the receiving space 12 through the component opening 11 (step H2).

[0078] The blind rivet nut 20 and the blind rivet bolt 22 may be plugged into the receiving opening 12. According to a further configuration, the thread element is a thread sleeve 40 with an inner thread 25 and an outer thread 42. The thread sleeve 40 is screwed into the receiving space 12 via the outer thread 42 in manufacturing step H2.

[0079] By doing so, the compression section 26; 26′ may be arranged adjacent to the widened molding section 14.

[0080] Subsequently, the thread element 20; 22; 40 is compressed parallel to its central longitudinal axis M within the receiving space 12 in the known manner (step H3). During the compression process, the shaft wall of the compression section 26; 26′ is folded radially to the outside. By doing so, a compression bead 27; 27′ is formed which is forced into the widened molding section 14.

[0081] A circumferential collar 13 which may project radially inwardly is arranged between the widened molding section 14 and the component opening 11. The collar 13 reduces a diameter of the component opening 11 compared with an inner diameter of the molding section 14. Based on this construction, the compression bead 27 may form an axial undercut in the molding section 12 in the direction of the component opening 11 as well as in the direction of the cylinder like support section 16. By that, the blind rivet nut 20, the blind rivet bolt 22 and the thread sleeve 40 may be axially held and fixed in the receiving space 12.

[0082] According to a configuration of the manufacturing method of the component bond, a thread bolt (not shown) may be screwed into the inner thread 25 of the blind rivet nut 20, the blind rivet bolt 22 and the thread sleeve 40 in order to compress the blind rivet nut 20, the blind rivet bolt 22 and the thread sleeve 40. The shaft 24 with screwed-in thread bolt is pulled in the direction of the collar 28, 28′ against an axial retention force at the collar 28 of the blind rivet nut 20 or the blind rivet bolt 22 or at the collar 28′ of the thread sleeve 40. Due to the acting axial pulling force, the compression portion 26; 26′ folds radially outwardly in the compression bead 27 and into the widened molding section 14.

[0083] With respect to FIG. 7, the circumferential retaining collar 13 has, at the component opening 11, an axial extension h.sub.K parallel to the central longitudinal axis M. The axial extension h.sub.K of the collar 13 may guarantee a constructive basis for a press fit of the blind rivet nut 20 and the blind rivet bolt 22 at the collar 13, because the collar 28 and the compression bead 27 may support themselves at opposite sides of the retaining collar 30, which may be against one another. This implements a support of the retention of the blind rivet nut 20 and the blind rivet bolt 22 in the receiving space 12.

[0084] The retaining collar 13 may have an axial thickness h.sub.K in the range from 0.5 mm≤≤5 mm.

[0085] For receiving the compression bead 27, the molding section 14 may have an axial height h.sub.E in the range from 0.5 mm≤h.sub.E≤10 mm, and in some embodiments from 0.5 mm≤h.sub.E≤5 mm. In order to achieve an axial clamping of the compression bead 27 in the molding section 14, the height h.sub.E of the molding section 14 may be adapted to an axial thickness of the compression bead 27 to be expected. This has the stabilizing effect that additionally, the axial sides of the compression bead 27 may be supported at the inside of the molding section 14, after the compression bead 27 has been forced into the molding section 14 during the compression process.

[0086] According to a further embodiment, the molding section 14 may have a maximum inner diameter D.sub.1. The cylinder like support section 16 may have a maximum inner diameter D.sub.2. The inner diameter D.sub.1 of the molding section is configured larger than the inner diameter D.sub.2 of the cylinder like support section 16. This may apply to the additively manufactured components 10 for receiving the blind rivet nut 20 and the blind rivet bolt 22 as well as to the component 30 for receiving the thread sleeve 40 with compression portion 26′ (see FIGS. 7, 8, 9, 10). This adaptation of the inner diameters D.sub.1, D.sub.2 may support the formation of an undercut of the compression bead 27 within the receiving space 12 and thus the retention of the thread element 20; 22; 40 in the additively manufactured component 10; 30.

[0087] The inner diameters D.sub.1, D.sub.2 of the molding section 14 and the support section 16 fulfil the following relation:

0.6≤D.sub.2/D.sub.1≤0.95.

[0088] According to a further embodiment, the molding section 14 and/or the cylinder like support section 16 have a non-round inner contour 15/17. The non-round inner contour 15, 17 may include each shape which is capable of entering into a rotation-inhibitive positive engagement with an also non-round outer contour of the compression bead 27 and/or a non-round outer contour of the shaft 24. For this purpose, it may be sufficient when at least a partial surface of the compression bead abuts the inner side of the molding section 14 or a partial portion of the outer side of the shaft 24 abuts the inner side of the support section 16 in a form-fit manner.

[0089] In a radial cross section viewed through the molding section 14 and the support section 16 and the shaft 24, the following rotation-inhibitive contours for the shaft 24, the molding section 14 and the support section 16 are preferred: all n-angular shapes with n≥3, star-like shapes, rounded shapes of the above-mentioned, cross shapes, rectangular shapes, drop shapes, lens shapes, elliptical shape.

[0090] The above-mentioned shapes or contours, respectively, are schematically shown in a top view in FIG. 11 for example.

[0091] Furthermore, the non-round shape of the molding section 14 and of the support section 16 can also be described by a diameter variation of the inner diameter D.sub.1 and D.sub.2, because with an imagined rotation of the diameter D.sub.1 and D.sub.2 about the central longitudinal axis M, the same changes its length due to the rotation-inhibitive contour of the molding section 14 and of the support section 16 (also see FIGS. 7-9).

[0092] According to a further embodiment of the component bond C, the thread sleeve 40 may be fastened according to FIG. 5 in the component 30. Apart from the inner thread 25, the outer thread 23 and the compression bead 26, the thread sleeve 40 has a circumferential fastening collar 44 that is arranged at the end side. The outer thread 42 may engage an inner thread 32 of the support section 16.

[0093] In order to be able to fasten the fastening collar 44 against rotation in the component 30, the same has a non-round outer contour. This outer contour is constructed similarly as has been described with respect to the inner contour of the molding section 14 and the support section 16 (see FIGS. 7, 9).

[0094] In order to make a flush arrangement of the thread sleeve 40 with the component surface in the component bond C (see FIG. 6), an axial step 34 is provided adjacent the molding section 14. The axial step 14 constitutes a steplike connection between the outer component surface 36 and the molding section 14. Compared to the component 10, the axial step 34 increases the component opening 11 by the collar 13 radially returning into the component.

[0095] For holding the thread sleeve 40 via the rotation collar 44 against rotation, the axial step 34 has a non-round contour which may be in circumferential direction. It may also be formed polygon-like, wave-like, curvilinear or in another shape, as has been described above with respect to the non-round inner contour of the molding section 14 and the support section 16.

[0096] During the fastening of the thread sleeve 40 in the component 30, the compression portion 26′ is folded into the molding section 14. Furthermore, the fastening collar 44 may be forced or pressed into the axial step 34.

[0097] A further embodiment of the component bond D is shown in FIG. 12. The component bond D may consist of an additively manufactured component 50 with a cylindrical receiving space 52 starting at a component opening 51.

[0098] The cylindrical section 52 transitions into a truncated cone-like molding section 54 at the closed end of the receiving space 52. The truncated cone-like molding section 54 consists of a receiving gap 56 which surrounds a truncated cone-like mandrel 58. The truncated cone-like mandrel 58 protrudes in the direction of the component opening 51 and tapers in the direction of the component opening 51.

[0099] The cylindrical section 52 in combination with the truncated cone-like molding section 56 is adapted to a thread element 60 which consists of a hollow cylindrical thread sleeve 62 with a rivet base 64.

[0100] By means of a setting force F, the thread element 60 is pressed into the cylindrical section 52 (see FIG. 12). There, the rivet base 64 encounters the truncated cone-like mandrel 58 and is radially widened. At the same time the rivet base 64 is pressed into the receiving gap 56.

[0101] A non-round outer contour of the thread sleeve 62 may lead to the rotation inhibition of the thread element 60 in the component 50.