Method for manufacturing a composite component from a first component and a second component

Abstract

The present invention relates to a method for manufacturing a composite component from at least a first component (4) and a second component (6). According to the invention, the method comprises the following steps: providing a first component (4), wherein the first component (4) comprises or is composed of a microporous elastomer; providing a second component (6), wherein the second component (6) comprises or is composed of a thermoplastic polymer; extruding the second component (6); and applying a layer (8) of the extruded second component (6) onto the first component (4) by means of an application nozzle (18).

Description

[0001] This invention relates to a method for manufacturing a composite component from at least a first component and a second component, the method comprising: providing a first component, wherein the first component comprises or is composed of a microporous elastomer; and providing a second component, wherein the second component comprises or is composed of a thermoplastic polymer. The invention also relates to a composite component and an additive manufacturing apparatus for manufacturing the composite component.

[0002] The fabrication of a composite component comprising a first microporous elastomer component and a second thermoplastic polymer component is complex and can be achieved by combining the two components or by an injection molding process.

[0003] When prototyping composite components during the product design and development phase, the primary objective is to manufacture the composite components in a manner similar to that envisioned for mass production processes. However, regarding assembly, this process is not suitable for mass production and therefore cannot be used to gain manufacturing experience for large-scale production. Injection molding can theoretically be used for both small-scale and large-scale production processes; however, it is expensive for small quantities and prototypes because every adjustment in the composite component design requires tooling changes, which is associated with time, effort, and cost. Therefore, injection molding is generally not economically viable for manufacturing small quantities of composite components and their prototypes.

[0004] Therefore, the object of the present invention is to provide an alternative method for manufacturing composite components, specifically for small-scale and prototyping. Specifically, the object of the present invention is to provide a method that ensures the components of a composite component are securely connected to each other, while allowing the design of the composite component to be adjusted without requiring extensive tooling modifications.

[0005] This invention achieves its objective through a method comprising the following steps: extruding a second component, and applying the extruded second component layer to a first component using an application nozzle. By extruding and applying the second component layer to the first component, a robust connection between the two components is ensured, wherein the shape of the layer can be adjusted to form the geometry of the second component as needed. This method reduces the manufacturing costs of small series and prototypes. Furthermore, the design process for such composite components can be directly supported by real components, enabling shorter response times to customer requests. Consequently, a competitive advantage can be achieved. While the method is particularly advantageous for prototyping before large-scale production and for the production of the small series itself, it is also advantageous for manufacturing large-scale series of composite components.

[0006] According to one embodiment, the application nozzle is the application nozzle of an additive manufacturing apparatus, specifically a filament fabrication additive manufacturing apparatus, wherein a second component is applied to a first component using the additive manufacturing apparatus. With the aid of the additive manufacturing apparatus, the second component can be "printed" onto the first component in the desired shape and form. Using commercially available filament fabrication equipment reduces investment costs and development effort. When using filament fabrication equipment, the thermoplastic polymer of the second component can be provided as a filament that is easy to handle and replace. The use of the additive manufacturing apparatus ensures that prototypes can be designed with high flexibility and low turnaround time and cost.

[0007] According to another embodiment, during the application of the first layer, a nozzle is applied to contact the first component to force the extruded second component to at least partially enter the first component. In this way, adhesion between the first and second components is achieved, on the one hand, by means of mechanical bonding, and on the other hand, by means of chemical bonding. In other words, the thermoplastic polymer is at least partially injected into the microporous elastomer to establish a mechanical bond between the components. The top portion of the first layer forms a chemical bond with the microporous elastomer. In this way, the first and second components are firmly connected to each other without the need for additional bonding steps.

[0008] According to one embodiment, during the application of the first layer, a nozzle is applied to immerse the first component at an immersion depth, specifically in the range of 0.1 mm to 2 mm or 1% to 30% of the total height of the first component. Typically, the immersion depth can be selected based on the Shore hardness of the first component (i.e., the microporous elastomer). It has been found that a given range is beneficial in ensuring a strong connection between the two components and establishing both mechanical and chemical bonding.

[0009] According to another embodiment, the layer is a first layer, and the second component is applied to the first component in at least the second layer, with the second layer resting on the first layer. Specifically, the second layer is applied to the first layer without contacting the first component. This means that the second layer is preferably applied only to the first layer. According to one embodiment, additional layers are applied on the second layer, wherein these layers are arranged overlapping each other. In this way, the different layers can form the geometry of the second component.

[0010] According to one embodiment, the first and / or second and / or additional layers comprise a layer height of 0.05 mm to 0.4 mm, preferably 0.2 mm to 0.3 mm. It has been found that the mentioned height range is advantageous for printing thermoplastic polymers onto microporous elastomers. According to one embodiment, the microporous elastomer of the first component comprises or is composed of microporous polyurethane (specifically, microporous polyurethane foam). These microporous polyurethane foams provide beneficial damping properties.

[0011] In this context, a micropore refers to a pore with a diameter preferably from 0.01 mm to 0.5 mm, and particularly preferably from 0.01 mm to 0.15 mm.

[0012] A particularly preferred material is a microporous polyurethane elastomer, which, in a preferred embodiment, has a strength of 200 kg / m³ according to DIN 53420. 3 Up to 1,100 kg / m 3 Preferably 300kg / m 3 Up to 800kg / m 3 The density of this type of microporous polyurethane elastomer is also known as a volumetrically compressible material (or: volumetrically compressible structural material). Compared to other materials such as rubber, volumetrically compressible materials, as described above, have particularly advantageous advantages such as extremely high elastic deformation capacity and high durability.

[0013] This production process typically involves the reaction between isocyanate and a compound that is reactive with isocyanate.

[0014] Microporous polyurethane is typically produced in a mold in which reactive starting components react with each other. The molds used here are typically conventional molds, such as metal molds, whose shape ensures that the first element has the three-dimensional shape of the invention. In one embodiment, a foaming mold is used to produce the first element. The manufacturing process may, for example, use waterjet cutting.

[0015] Microporous polyurethane is a reaction product of diisocyanate, polyol, and water. The diisocyanate is preferably selected from the group consisting of 1,4-phenylene diisocyanate (PPDI), 1,4-cyclohexane diisocyanate, 4,4'-diphenylmethane diisocyanate, 3,3'-dimethylbiphenyl-4,4'-diisocyanate, and 1,5-naphthalene diisocyanate, or mixtures thereof. More preferably, the diisocyanate is selected from the group consisting of 4,4'-diphenylmethane diisocyanate and 1,5-naphthalene diisocyanate, or mixtures thereof. The most preferred diisocyanate is 1,5-naphthalene diisocyanate. The polyol is preferably a bifunctional polyol. The number average molecular weight of the polyol is between 0.5 × 10⁻⁶. 3 g / Mol and 10×10 3 Between g / Mol, more preferably between 0.6 × 10⁻⁶ g / Mol. 3 g / Mol and 6×10 3 Between g / Mol, more preferably between 0.7 × 10⁻⁶ g / Mol. 3 g / Mol and 4×10 3 Between g / Mol.

[0016] In the context of this invention, the number-average molecular weight Mn is preferably determined by gel permeation chromatography, more preferably according to DIN EN ISO 13885-2:2020; and dimethylformamide (DMF) is used as a solvent.

[0017] The polyol for microporous polyurethane is preferably a polyester glycol or a polyether glycol, or a mixture thereof. The polyether glycol is preferably a polymeric glycol based on ethylene oxide, propylene oxide, tetrahydrofuran, or a mixture thereof. A more preferred polyether glycol is polytetrahydrofuran (PTHF).

[0018] The polyester diol of microporous polyurethane is preferably a reaction product of dicarboxylic acid and diol.

[0019] Preferred dicarboxylic acids are one of C4 to C12 dicarboxylic acids or a mixture thereof. Preferred diols are one of C2 to C14 diols or a mixture thereof.

[0020] More preferably, the C4 to C12 dicarboxylic acids are aromatic dicarboxylic acids or aliphatic dicarboxylic acids or mixtures thereof.

[0021] Preferably, the aliphatic dicarboxylic acid is selected from succinic acid, glutaric acid, adipic acid, octanoic acid, azelaic acid, and sebacic acid, or a mixture thereof.

[0022] Preferably, the aromatic dicarboxylic acid is selected from phthalic acid, isophthalic acid, and terephthalic acid, or a mixture thereof.

[0023] More preferably, the dicarboxylic acid is selected from the group consisting of succinic acid, glutaric acid, adipic acid, octanoic acid, phthalic acid, isophthalic acid, and terephthalic acid, or a mixture thereof.

[0024] More preferably, the dicarboxylic acid is selected from the group consisting of adipic acid, octanoic acid, and phthalic acid, or mixtures thereof. The most preferred dicarboxylic acid is adipic acid.

[0025] The diol in the polyester of the microporous polyurethane, which is a reaction product of dicarboxylic acid and diol, is preferably selected from ethylene glycol, 1,4-butanediol, 1,6-hexanediol, 2-methyl-1,3-propanediol, 3-methyl-1,5-pentanediol, 2,2-dimethylpropane-1,3-diol, or mixtures thereof.

[0026] In a preferred embodiment of the microporous polyurethane, a blowing agent is also used. This could be a low-boiling-point liquid that evaporates under the influence of the exothermic addition polymerization reaction of the polyurethane.

[0027] Preferably, additives are used in the production of microporous polyurethane. These include, for example, surfactants, foam stabilizers, cell conditioners, fillers, flame retardants, nucleation delayers, stabilizers, microbial inhibitors, lubricants and release agents, dyes and pigments.

[0028] Microporous polyurethanes are preferably prepared via a prepolymerization process. This means that the diisocyanate is reacted with the full amount of the polyol before the addition of other components containing water, or the diisocyanate is reacted with the major portion (preferably greater than 50% by weight) of the polyol before the addition of the remaining polyol containing water and (if applicable) other components.

[0029] According to one embodiment, the thermoplastic polymer of the second component includes at least one of the following: -Polyamide, -Thermoplastic polyurethane, -Polypropylene, -Polyethylene.

[0030] The aforementioned material has been found to be beneficial for application to the first component and can be used in filament-based additive manufacturing processes.

[0031] Preferably, the thermoplastic polyurethane is a reaction product of the constituent components (diisocyanate, polyol, and chain extender). The diisocyanate is preferably selected from the group consisting of organic polyisocyanates, more preferably organic diisocyanates; a further preferred isocyanate is selected from the group consisting of aliphatic, alicyclic, aryliphatic, and aromatic isocyanates, or mixtures thereof. Aliphatic isocyanates are preferred when stability against electromagnetic waves, such as light, is important, while aromatic polyisocyanates are preferred when high mechanical strength of the thermoplastic polyurethane is required. More preferably, the diisocyanate is selected from... Diphenylmethane diisocyanate (MDI), hexamethylene diisocyanate (HDI) as well as Methylene dicyclohexyl diisocyanate (H12MDI), or mixtures thereof; more preferably, the diisocyanate includes 2,2'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, or 4,4'-diphenylmethane diisocyanate, or mixtures thereof, with 4,4'-diphenylmethane diisocyanate being particularly preferred. The polyol used to react the thermoplastic polyurethane has, on a statistical average, at least 1.8 and at most 2.4 Zerewitinoff active hydrogen atoms. This value is also referred to as the functionality of the polyol. The functionality is preferably between 1.8 and 2.2, more preferably 2.0. Preferably, the polyol has a functionality between 0.5 × 10⁻⁶. 3 g / mol and 8×10 3 Between g / mol, more preferably between 0.6 × 10⁻⁶ g / mol3 g / mol and 6.0×10 3 Between g / mol, or even more preferably between 0.6 × 10⁻⁶ g / mol. 3 g / mol and 3.0×10 3 Number-average molecular weights between g / mol.

[0032] More preferred polyols for thermoplastic polyurethanes include polyols selected from the group consisting of polyether diols, polyester diols, and polycarbonate diols, or mixtures thereof.

[0033] The preferred polyether diol used to react thermoplastic polyurethane is selected from the group consisting of polyethylene glycol, poly-1,3-propanediol and poly-1,4-butanediol or mixtures thereof.

[0034] Particularly preferred is polytetrahydrofuran (PTHF), preferably having a number-average molecular weight Mn of 0.6×10³ g / mol to 2.0×10³ g / mol, more preferably 0.7×10³ g / mol to 1.3×10³ g / mol, and most preferably 1.0×10³ g / mol.

[0035] Preferred polyester polyols for reacting thermoplastic polyurethanes include lactones, preferably polymers of polycaprolactone, and those obtained by polymerization of dicarboxylic acids with polyols, or mixtures thereof.

[0036] Polycaprolactone preferably has a number-average molecular weight of 0.7 × 10³ g / mol to 2.5 × 10³ g / mol.

[0037] In another preferred embodiment, the polyester diol is obtained by polymerizing a dicarboxylic acid with a polyol. Preferred dicarboxylic acids are one of C4 to C12 dicarboxylic acids or mixtures thereof. Preferred polyols are one of C2 to C14 diols or mixtures thereof. More preferably, the dicarboxylic acid is selected from the group consisting of succinic acid, glutaric acid, adipic acid, octanoic acid, phthalic acid, isophthalic acid, and terephthalic acid, or mixtures thereof. The most preferred dicarboxylic acid is adipic acid.

[0038] The polyol is preferably selected from 1,2-ethylene glycol, diethylene glycol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, 1,6-hexanediol, 1,10-decanediol, 2,2-dimethyl-propane-1,3-diol, 1,3-propanediol, 2-methyl-1,3-propanediol, and dipropylene glycol, or mixtures thereof. More preferably, the polyol is selected from the group consisting of 1,2-ethylene glycol, diethylene glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,10-decanediol, or mixtures thereof. Most preferably, the diol is selected from the group consisting of 1,4-butanediol, a mixture of 1,2-ethylene glycol and 1,4-butanediol, or a mixture of 1,4-butanediol and 1,6-hexanediol.

[0039] Preferred polycarbonate diols are aliphatic polycarbonate diols, more preferably OH-bifunctional polycarbonate diols. More preferably, the polycarbonate diol is based on 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, and 3-methylpentane-(1,5)-diol, or mixtures thereof.

[0040] Another preferred polycarbonate diol is based on a mixture of 1,4-butanediol and 1,6-hexanediol, a mixture of 1,5-pentanediol and 1,6-hexanediol, or a polycarbonate diol based on 1,6-hexanediol, or a mixture thereof.

[0041] The polycarbonate diol preferably has a number-average molecular weight Mn between 1×10³ and 5×10³ g / mol, more preferably between 1.4×10³ g / mol and 3×10³ g / mol, more preferably between 1.8×10³ g / mol and 2.2×10³ g / mol, and even more preferably 2.0×10³ g / mol.

[0042] The chain extender in thermoplastic polyurethane is preferably aliphatic, araliphatic, aromatic, or alicyclic, or a mixture thereof. The chain extender preferably has a molecular weight between 50 g / mol and 499 g / mol. More preferably, the chain extender contains 2 to 10 carbon atoms in the alkylene group, more preferably 3 to 8 carbon atoms, and even more preferably an alkyl glycol. The alkyl glycol preferably has only primary hydroxyl groups. Particularly preferred alkyl glycols are selected from 1,2-ethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, hydroquinone bis(β-hydroxyethyl) ether (HQEE), diallyl glycol, trialkyl glycol, tetraalkyl glycol, pentaalkyl glycol, hexaalkyl glycol, heptaalkyl glycol, octaalkyl glycol, nonaalkyl glycol, or decaalkyl glycol, and also preferably the corresponding oligoalkylene glycols and / or polyalkylene glycols, or mixtures thereof.

[0043] More preferably, the chain extender is selected from the group consisting of ethylene glycol, propylene glycol, butanediol, hexanediol, or mixtures thereof; more preferably, it is selected from the group consisting of 1,2-ethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, or mixtures thereof; more preferably, the chain extender is selected from 1,4-butanediol and 1,3-propanediol, or mixtures thereof; and most preferably, the chain extender is 1,4-butanediol.

[0044] In a highly preferred embodiment, the thermoplastic polyurethane is a reaction product of 4,4'-diphenylmethane diisocyanate, polytetrahydrofuran, and 1,4-butanediol. The polytetrahydrofuran (PTHF) in the thermoplastic polyurethane preferably has a number-average molecular weight (Mn) of 0.6 × 10³ g / mol to 2.5 × 10³ g / mol, more preferably 0.8 × 10³ g / mol to 1.2 × 10³ g / mol, and most preferably 1.0 × 10³ g / mol.

[0045] Thermoplastic polyurethane preferably has a Shore hardness between 80 Shore A and 80 Shore D. The Shore hardness is preferably measured according to DIN ISO 7619-1: 2016. Very preferably, the thermoplastic polyurethane has a Shore hardness between 58 Shore A and 90 Shore A, between 90 Shore A and 100 Shore A, or between 65 Shore A and 75 Shore D.

[0046] In a preferred embodiment, the first and / or second components include an auxiliary agent or additive. The auxiliary agent or additive is a single substance or a mixture of at least two substances. In a preferred embodiment, the auxiliary agent or additive is selected from the group consisting of: surfactants, fillers, flame retardants, nucleating agents, oxidation stabilizers, lubricants, release agents, dyes, catalysts, pigments, inorganic or organic fillers, reinforcing agents, plasticizers, antistatic agents, stabilizers, preferably stabilizers resistant to hydrolysis, light, heat, or discoloration, or mixtures thereof.

[0047] According to one implementation, the nozzle is applied at a depth of 0.5 mm. 3 / s to 25mm 3 The second component is applied at a volumetric flow rate of / s. It has been found that the aforementioned flow rate is beneficial for applying thermoplastic polymers onto microporous elastomers.

[0048] According to one embodiment, the second component comprises a Shore hardness of 70A-90D, specifically 85A-74D. The mentioned Shore hardness range allows for chemical and mechanical bonding between the microporous elastomer of the first component and the thermoplastic polymer of the second component.

[0049] According to one embodiment, the surface of the first component on which the first layer of the second component is applied is flat. In this way, the additive manufacturing or 3D printing process can be advantageously applied to the first component, specifically the planar portion of the first component.

[0050] In another aspect, the present invention relates to a composite component manufactured by a method according to any of the foregoing embodiments. Because the second component is mechanically and chemically bonded to the first component, the composite component manufactured by the method according to the invention also includes a unique structure different from composite components manufactured, for example, by bonding or injection molding.

[0051] According to one embodiment, the composite component is a two-component damping element, specifically a spring support comprising a base and a spring receiving portion, wherein the base comprises or is composed of microporous polyurethane, and wherein the receiving portion for the spring is made of or is composed of thermoplastic polyurethane. Such a two-component damping element is an example of a composite component that can be manufactured by the method according to the invention. Prototypes of such two-component damping elements can advantageously be manufactured with high design flexibility, low turnaround time, and low cost.

[0052] The composite component according to the invention utilizes the same advantages and preferred embodiments as the method, and vice versa. Therefore, the preferred embodiments of the method are also the preferred embodiments of the composite component of the invention, and vice versa.

[0053] In another aspect, the invention also relates to an additive manufacturing apparatus for producing composite components, comprising an application nozzle and a data processing device including components for performing the methods of any of the foregoing embodiments. The additive manufacturing apparatus according to the invention utilizes the same advantages and preferred embodiments as the methods and composite components of the invention. Therefore, preferred embodiments of the methods and composite components are also preferred embodiments of the additive manufacturing apparatus, and vice versa.

[0054] To gain a more complete understanding of the invention, it will now be described in detail with reference to the accompanying drawings. The detailed description will illustrate and describe what is considered to be the preferred embodiments of the invention. Of course, it should be understood that various modifications and changes in form or detail can be readily made without departing from the spirit of the invention. Therefore, it is intended that the invention is not limited to the exact forms and details shown and described herein, nor to anything less than the entirety of the invention disclosed herein and claimed below.

[0055] Furthermore, the features described in the specification, drawings, and claims that disclose the invention may be necessary for the invention to be considered individually or in combination. Specifically, any reference numerals in the claims should not be construed as limiting the scope of the invention. The word "comprising" does not exclude other elements or steps. The words "a" or "an" do not exclude a plurality.

[0056] The invention will now be described with reference to the accompanying drawings, which illustrate, by way of example and not limitation, one of several possible embodiments of the method for manufacturing the composite component proposed herein, and wherein: Figure 1 A block diagram of the method according to the present invention is shown; Figure 2 A schematic overview of an additive manufacturing apparatus is shown, in which a second component is applied to a first component. Figure 3 A schematic diagram illustrates the method steps for applying the first layer of the second component to the first component; and Figure 4 A schematic diagram of the method steps for applying a second layer of a second component to a first component is shown.

[0057] Figure 1 It is shown that it is used to manufacture such as by at least the first component 4 and the second component 6. Figures 2 to 4The method 100 of the composite component 2 shown includes: providing 102 a first component 4, wherein the first component 4 comprises or is composed of any microporous elastomer; providing 104 a second component 6, wherein the second component 6 comprises or is composed of a thermoplastic polymer; extruding 106 the second component 6; and applying 108 a layer 8 of the extruded second component 6 onto the first component 4 by means of an application nozzle 18.

[0058] The method is in Figure 2 The example is illustrated graphically. Figure 2 An additive manufacturing apparatus 16 is shown. The additive manufacturing apparatus 16 includes an application nozzle 18 that can be adjusted in three dimensions. The additive manufacturing apparatus 16 is configured to extrude a second component 6, specifically a filament of the second component 6. The second component 6 is then applied layer by layer onto the first component 4 by means of the application nozzle 18.

[0059] The first component 4 includes or is composed of a microporous elastomer. The second component 6 includes or is composed of a thermoplastic polymer. The additive manufacturing equipment 16 can be a fused wire additive manufacturing equipment 16, such as... Figure 2 exemplified. like Figure 2 As shown at the top, the filament of the second component 6 is supplied to the nozzle 18. Figure 2 In this process, the first layer 8, the second layer 10, and an additional layer 12 have been applied to the first component 4. These layers include a layer height h. 层 The first component 4 has a total height h. 总 The first component 4 and layers 8, 10, and 12 that form the second component 6 form the composite component 2.

[0060] exist Figure 3 The diagram illustrates the application of a first layer 8 to a first component 4. During the application of the first layer 8, an application nozzle 18 contacts the first component 4 to force the extruded second component 6 at least partially into the first component 4. Specifically, during the application of the first layer 8, the application nozzle 18 is immersed into the first component 4 to an immersion depth d. In this way, not only is a chemical bond achieved between the first layer 8 of the second component 6 and the first component 4, but also a mechanical bond is achieved because the thermoplastic polymer of the second component is partially injected into the microporous elastomer of the first component 4. The chemically bonded areas are labeled with reference numeral 20, and the mechanically bonded areas are labeled with reference numeral 22. The first component 4 includes a surface 14 that is substantially planar to allow the application of the first layer 8 and thus the printing process.

[0061] Figure 4The application of the second layer 10 is illustrated. The second layer 10 is applied only to and rests on the first layer 8. In other words, the second layer 10 and all other layers are applied without contacting the first component 4. Furthermore, the application nozzle 18 does not contact or even penetrate the first component 4. This is only done for the first layer 8. The first layer 8 and the second layer 10 form a jump height h. 跳跃 .

[0062] The microporous elastomer of the first component 4 includes microporous polyurethane, specifically microporous polyurethane foam. The thermoplastic polymer of the second component 6 includes at least one of the following: polyamide, thermoplastic plastic made of polyurethane, polypropylene, or polyethylene. Applied through nozzle 18 at a rate of 0.5 mm... 3 / s to 25mm 3 The second component 6 is applied at a volumetric flow rate of / s.

[0063] With the aid of the illustrated method 100, the microporous elastomer first component 4 and the thermoplastic polymer second component 6 are firmly joined together, wherein the additive manufacturing process allows for high design flexibility, low turnaround time and low production cost for manufacturing such composite components 2.

[0064] List of reference numerals 2 Composite Components 4. First component including microporous elastomer 6. A second component comprising a thermoplastic polymer 8 First Floor 10 Second layer 12 Other layers 14 Surface of the first component 16 Additive Manufacturing Equipment 18 Apply nozzle 20 chemically bound regions 22 Mechanical Integration Area 100 methods 102 provides the first component 104 provides a second component 106 Extrusion Second Component 108. The extruded second component is applied to the first component. d Immersion depth h 总 Total height of the first component h 层 Floor height h 跳跃 Jump height

Claims

1. A method (100) for manufacturing a composite component (2) from at least a first component (4) and a second component (6), the method (100) comprising: - Provide (102) a first component (4), wherein the first component (4) comprises or is composed of a microporous elastomer, - Provide (104) a second component (6), wherein the second component (6) comprises or is composed of a thermoplastic polymer, - Extrusion (106) of the second component (6), and - The extruded second component (6) layer (8) is applied (108) to the first component (4) by means of the application nozzle (18).

2. The method (100) according to claim 1. The application nozzle (18) is an application nozzle (18) of an additive manufacturing apparatus (16), specifically a filament manufacturing additive manufacturing apparatus (16), and wherein the second component (6) is applied to the first component (4) using the additive manufacturing apparatus (16).

3. The method (100) according to any one of the preceding claims. The layer (8) is a first layer, and during the application of the first layer (8), the application nozzle (18) contacts the first component (4) to force the extruded second component (6) to enter at least partially into the first component (4).

4. The method (100) according to claim 3. During the application of the first layer (8), the application nozzle (18) is immersed in the first component (4) to an immersion depth (d), specifically wherein the immersion depth (d) is in the range of 0.1 mm to 2 mm or in the total height (h) of the first component (4). 总 The percentage ranges from 1% to 30%.

5. The method (100) according to any one of the preceding claims. The layer (8) is a first layer (8), and the second component (6) is applied to the first component (4) in at least a second layer (10), which rests on the first layer (8).

6. The method (100) according to claim 5. The second layer (10) is applied to the first layer (8) without contacting the first component (4).

7. The method (100) according to any one of the preceding claims. The layer (8) is a first layer (8), and the first layer (8) and / or the second layer (10) and / or the additional layer (12) comprises a layer height (h) of 0.05 mm to 0.4 mm, preferably 0.2 mm to 0.3 mm. 层 ).

8. The method (100) according to any one of the preceding claims. The microporous elastomer of the first component (4) includes microporous polyurethane, specifically microporous polyurethane foam.

9. The method (100) according to any one of the preceding claims. The thermoplastic polymer of the second component (6) includes at least one of the following: -Polyamide, - A thermoplastic made of polyurethane. -Polypropylene, -Polyethylene.

10. The method (100) according to any one of the preceding claims. The application nozzle (18) is used to apply 0.5 mm. 3 / s to 25mm 3 The second component (6) is applied at a volumetric flow rate of / s.

11. The method (100) according to any one of the preceding claims. The second component (6) includes Shore hardness of 70A-90D, specifically 85A-74D.

12. The method (100) according to any one of the preceding claims. The surface (14) of the first component (4) on which the first layer (8) of the second component (6) is applied is flat.

13. A composite component (2) manufactured by the method (100) according to any one of the preceding claims.

14. The composite component (2) according to claim 13, wherein the composite component (2) is a dual-component damping element, specifically a spring support comprising a base and a receiving portion for a spring, wherein the base comprises or is composed of microporous polyurethane, and wherein the receiving portion for the spring is made of thermoplastic polyurethane or is composed of thermoplastic polyurethane.

15. An additive manufacturing apparatus (16) for manufacturing a composite component (2), the additive manufacturing apparatus comprising an application nozzle (18) and a data processing device, the data processing device comprising components for performing the method (100) according to any one of claims 1 to 12.

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