Method for the production of a component having a rod-shaped metal body by overmolding

Abstract

The invention relates to a method for producing a component (1), for example a rotor, comprising a rod-shaped metal body (3), for example a rotor shaft, comprising the following process steps: providing a rod-shaped body (3); introducing a protrusion or recess (10-10") in order to form a surface structure on a surface portion of the rod-shaped body (3); overmolding the surface portion of the rod-shaped body (3) by means of a plastic material in order to form a connecting body (6), for example a rotor hub. The process of overmolding the surface portion of the rod-shaped body (3) produces a connection between the rod-shaped body (3), for example a rotor shaft, and the connecting body (6), for example a rotor hub. Before overmolding with the plastic material, a functional device (2) is optionally provided and positioned, for example consisting of a magnetic coil with a back iron (8) or a permanent magnet (7, 7').

Description

[0001] This invention relates to a method for manufacturing a component comprising a rod-shaped metal body. Corresponding methods for producing rod-shaped metal bodies, for example, equipped with functional devices, are known in the prior art. Therefore, it is known to encapsulate the rod-shaped body with a plastic part during injection molding. Typically, the function of the component to be manufactured is achieved by the molded plastic part itself and / or the rod-shaped body. However, this may limit the functions that the component can achieve.

[0002] The object of the present invention is achieved by describing in detail a method, particularly a simple, rapid and cost-effective measure, that enables the production of components comprising rod-shaped metal bodies and functional devices, characterized by robustness and a variety of possibilities for realizing functions.

[0003] This objective is achieved by the method for producing a component comprising a rod-shaped metal body according to claim 1. The related dependent claims relate to possible embodiments of the method. Furthermore, this objective is achieved by the component according to claim 28 and the apparatus according to claim 29.

[0004] This invention relates to a method for manufacturing a component, particularly comprising a functional device and a rod-shaped metal body. The method is used to provide one or more rod-shaped metal bodies. Protrusions and / or recesses are introduced into the surface portions of the rod-shaped body to form surface structures. Optionally, a functional device may be provided, initially formed as a separate body from the rod-shaped metal body. In another method step, the surface portions of the molded rod-shaped body are covered with a plastic material to form a connector, wherein a connection between the rod-shaped body and the connector is created by covering the surface portions of the molded rod-shaped body. In other words, by covering the surface portions of the molded rod-shaped body, a good mechanical connection is created, as the plastic material forms a tight connection with the protrusions and recesses of the surface structure, i.e., a form-fit connection, for example. The molded plastic material can arrange itself in the recesses and / or around the protrusions, and thus also form a load-bearing connection due to the large connecting surface.

[0005] For example, the method may include providing a functional device, wherein a connection between the rod and the functional device is created by overmolding a surface portion of the rod. Overmolding the rod creates a load-bearing connection between the rod and the functional device. For example, a rigid connection between the rod and the functional device may be created by a connector. For example, if the rod is formed as multiple parts, at least two parts to be assembled (parts to be joined together) used to form the rod may be connected to each other by press fit and / or material bonding and / or form fit before and / or during the process of overmolding the surface portion of the rod to form the connector.

[0006] The functional device may include at least one functional element optimized for the intended application of the component, such as at least one magnetically active element and / or at least one bearing sleeve and / or at least one winding element. Therefore, the functional device may optionally include, for example, an assembly of at least two functional elements or functional components. For example, an additional functional element is fastened (especially mounted) to a first functional element.

[0007] At least one functional element of a component formed as a magnetically active element may be, for example, an element having a ferromagnetic material, which is itself magnetic or magnetizable. A magnetizable magnetically active element may, for example, be an electric coil. The magnetically active element may also have a passive magnetic operation mode, i.e., for example, the magnetically active element itself does not generate a magnetic field, but the main magnetic field can be permanently or temporarily influenced by the magnetically active element, for example, it can be strengthened or guided. For example, at least one functional element may be an iron element or an iron ladle having a set of iron elements. Typically, at least one magnetically active element can be used as a functional element, which may be a magnet (e.g., a permanent magnet), a magnetizable element, or an element that influences a magnetic field. Because at least one functional element is manufactured or supplied separately from the rod body, and separately from the overmolding of the connector or rod body, the functional element can be designed with considerable freedom in terms of its mechanical and / or chemical properties.

[0008] In advantageous embodiments, this component serves as part of a motor (particularly an electric motor). The electric motor can, for example, be used for auxiliary functions in a vehicle (preferably a land vehicle, particularly a bus or commercial vehicle). In a vehicle, the electric motor used for auxiliary functions performs functions not intended for vehicle traction or propulsion.

[0009] It is possible that, prior to the process of overmolding the surface portion of the rod-like body to form the connector, the retainer is fastened to at least one functional element of the functional device during the joining process. For example, prior to the process of overmolding the surface portion of the rod-like body to form the connector, the retainer is at least partially (preferably primarily, particularly preferably completely) overmolded to at least one functional element of the functional device using a plastic material. Thus, prior to overmolding the surface portion, the retainer, as a component whose shape is already defined, can be fastened to the functional element by press fitting and / or material bonding and / or form fit. According to an exemplary embodiment, the retainer can be formed by at least partially overmolding the functional element. The retainer and the functional element can therefore form components of the functional device. Because the retainer is overmolded to at least one functional element of the functional device, the functional device can form a hybrid intermediate component and be connected to the rod-like body as a hybrid intermediate component during the process of overmolding the surface portion of the rod-like body. The material used to form the retainer can be the same as or different from the material used to form the connector. As the plastic material used to form the retainer and the connector, materials with similar coefficients of thermal expansion are preferred; for example, the difference in coefficients of thermal expansion is at most 1.0%, preferably at most 0.25%, particularly preferably at most 0.10%, most preferably at most 0.01%, and even more preferably at most 0.001%. The retainer may, for example, have a retaining function for another component (e.g., for at least one iron element).

[0010] The retainer can be formed, for example, in a ring shape, particularly in a closed ring shape. Therefore, the retainer can have a radially inward cavity extending outward (particularly without gaps). Within this cavity, rod-like bodies and / or connecting bodies can be arranged at least in segments in the final assembled state.

[0011] It is possible that the component to be produced is designed to respond (at least partially) to magnetic influences in its intended use in a targeted manner. Therefore, it is possible that at least one functional element is a magnetically active element. Optionally, in addition to making at least one functional element a magnetically active element, a ferrule consisting of at least two iron elements may also be at least partially overmolded during the process of at least partially overmolding at least one functional element to form a retainer. As an alternative to or in addition to a ferrule consisting of at least two iron elements, a magnetic flux carrying element, i.e., an element that responds to a magnetic field, may also be used. The retainer thus holds at least one magnetically active element and the ferrule. This can thus produce a sub-assembly consisting of at least one magnetically active element, the ferrule, and the retainer. This sub-assembly can then be connected to a rod-shaped body by overmolding a rod-shaped metal body during a downstream overmolding process for forming a connector. In other words, the retainer, together with at least one magnetically active element and the ferrule, can form an assembly, particularly an assembly fixed within itself. This component can form a magnetic action device, which is arranged in a defined orientation and / or position relative to the rod (particularly relative to the shaft) in upstream and downstream method steps, and is connected to the rod or shaft by a plastic material used to form the connecting body or hub during the overmolding of the surface portion of the rod or shaft. Alternatively to the ladle, during at least partial overmolding, the retainer can also contact or at least segmentally surround another functional element (particularly a magnetic flux-carrying element) different from the ladle, as well as at least one first functional element. At least one iron element of the ladle can be, for example, a sheet metal element. Optionally or additionally, at least one iron element of the ladle can be a sintered component. The iron element comprises at least iron as a component, for example, the iron element is formed of steel.

[0012] In an advantageous embodiment, a ladle having at least two iron elements and at least one functional element can be provided, which is fastened to a rod-like body by forming a connector without a retainer. Thus, for example, the connector can directly contact a portion of at least one functional element and a portion of the ladle without being pre-fixed to the ladle by any possible means of the retainer and at least one functional element, which subsequently forms part of the component.

[0013] At least one functional element (particularly all functional elements of the rod-shaped metal body with functional devices) and the retainer can be, for example, overmolded with plastic material to form a connector, such that the connector maintains contact with the retainer and at least one functional element. In other words, by means of the connector, not only can there be a direct and / or dedicated connection between the rod-shaped body and the functional device via the connector, but also a direct connection between the retainer and the functional element via the connector. For example, at least one functional element can be in contact with the retainer at a first connecting portion and can be in contact with the connector at at least one additional connecting portion. The connector can, for example, maintain contact with the retainer, at least one functional element, and the ladle. Alternatively or additionally, for example, at least one functional element (particularly all functional elements) may not be in direct contact with the connector and may be connected to the connector only through the retainer and / or the ladle.

[0014] In an optional method step, the rod and the retainer carrying at least one functional element can be arranged to be relatively positioned in a defined manner, wherein after the defined relative positioning has been achieved, an overmolding process for forming the connector is performed. For this purpose, the injection molding tool for the injection molding process of forming the connector can be loaded with the rod and the retainer carrying at least one functional element before the injection molding process, wherein the injection molding is performed after this event. The relative positioning of the functional element / retainer assembly and the rod forms a cavity in which plastic material is introduced. Any adverse tolerance effects of the functional device and / or the retainer and / or the rod can be minimized through targeted and particularly suitable relative positioning of the functional element / retainer assembly relative to the rod.

[0015] Because the retaining device is first molded onto the functional device to produce the functional device as a geometrically defined body, and then the retaining device / functional device assembly is targeted for alignment with the rod, this relative alignment can be used to compensate for or reduce any differences between the retaining device / functional device assembly and / or the rod, particularly regarding imbalance. Adjustments to the relative alignment can also be used for parts that do not form a retainer, such that the first functional device is aligned or positioned relative to the first rod in the first relative alignment and is ultimately overmolded to form a connector. In a second injection molding process for forming a connector of another part, different relative alignments may occur compared to those used in the previously produced part, depending on the physical and / or chemical differences between the functional device and / or the rod, compared to the corresponding portion of the previously produced part. For example, based on the difference between the imbalance behavior of the functional device and / or the rod of the first part and the imbalance behavior of the functional device and / or the rod of the other part, different alignments or positions of the retaining device and / or the rod can be assumed for the other part.

[0016] In a preferred embodiment, protrusions and / or depressions for forming the surface structure are introduced into the rod-shaped body using at least one laser beam. In other words, the laser beam can act on the metal rod-shaped body to achieve a target form and / or target configuration of the surface structure. The rod-shaped body can be formed, for example, of steel, particularly of hardened steel. As the material for the rod-shaped body, stainless steel (e.g., a Ni-Cr metal alloy) can be used. For example, the material used as the rod-shaped body has a hardness of 30 to 85 HRC, preferably 45 to 75 HRC, particularly preferably 50 to 70 HRC, and most preferably 55 to 65 HRC. The laser beam acting on the surface of the metal body can, for example, use the following laser parameters. When the metal rod-shaped body is acted upon by at least one laser beam, a structured form with microscopic and macroscopic structural portions, or only microscopic structural portions, or only macroscopic structural portions, can be produced. Therefore, the laser-assisted structuring formed here can have protrusions and / or depressions in the micrometer range (i.e., from 1.0 micrometer to 999 micrometers) or in the macroscopic range (i.e., greater than 999 micrometers). It is possible for laser action to prevent the formation of intentionally or explicitly formed protrusions and / or depressions in the nanometer range (i.e., less than 1.0 micrometers).

[0017] The surface structure can be, for example, in the form of multiple local region segments, wherein the local region segments can at least segmentally (preferably primarily, particularly preferably completely) have a straight orientation. For example, at least one local region segment (especially all local region segments) of the rod-like body can have a width of 0.02 mm to 1.0 mm, preferably 0.05 mm to 0.60 mm, particularly preferably 0.10 mm to 0.40 mm, most preferably 0.15 mm to 0.30 mm, and further preferably 0.20 mm. For example, a surface structure can be produced consisting of at least two segmented straight local region segments that intersect and / or cross each other. Thus, for example, a cross can be formed by two straight partial region segments that intersect each other at an angle preferably 30° to 60°, particularly preferably 90°.

[0018] Alternatively or additionally, at least one local region segment (especially all local region segments) of the rod may have a length of 0.25 mm to 2.0 mm, preferably 0.35 mm to 1.4 mm, particularly preferably 0.5 mm to 0.9 mm, and most preferably 0.7 mm. Alternatively or additionally, the aspect ratio of at least one local region segment (especially all local region segments) may be 1.75 to 5.5, preferably 2.5 to 4.5, particularly preferably 3.0 to 4.0, most preferably 3.1 to 3.8, and further preferably 3.3 to 3.7.

[0019] Optionally or additionally, certain sections can be shaped to form wavy or zigzag routes. In particular, in this case, straight sections form rising waves, and adjacent sections form falling waves, thus creating a waveform.

[0020] Alternatively, the ratio of the minimum spacing between two adjacent local region segments, particularly the minimum axial spacing (i.e., the spacing extending along the rotation axis of the rod-like body), to the width of the adjacent local region segments is at least 0.9, preferably 1.2, particularly preferably 1.35, most preferably 1.4, and / or the maximum ratio is 2.5, preferably 2.1, particularly preferably 1.8, most preferably 1.65, and further preferably 1.5.

[0021] It is possible that the surface structure is formed in the form of multiple localized segments, wherein the localized segments at least partially (preferably mainly, particularly preferably completely) have or form a cross and / or star-shaped structure. Thus, for example, two particularly straight localized segments may intersect or cross to form a cross and / or star-shaped structure. The cross structure can be generated, for example, by the intersection of lines (particularly two preferred straight lines) passed through by a laser on the surface of the shaft, thereby forming localized segments with a cross shape. From a top view of the rod-shaped body, the star and / or cross-shaped structure can have a star or cross shape, i.e., when viewed in a plane parallel to the tangent of the circular (particularly cylindrical) rod-shaped metal body.

[0022] The surface structure can be configured such that a first group of local region segments and at least another group of local region segments each form a row, particularly a straight line. In other words, three or more local region segments can be arranged as a group on a line (preferably a straight line). This straight line can extend, for example, parallel to the longitudinal axis of the rod, or can have a threaded or helical path around the longitudinal axis of the rod, particularly having a constant pitch, a constantly varying pitch, or a non-constant pitch at least segmentally (preferably primarily, especially preferably uniquely). The threaded or helical path of the straight line on which a group of local region segments is arranged can at least once encircle a circumference perpendicular to the longitudinal axis of the rod, or can not completely encircle a circumference perpendicular to the longitudinal axis of the rod.

[0023] The connector may, for example, extend completely around the rod-like body on its side surface in at least one transverse plane. For instance, the connector may surround the rod-like body in a sleeve-like or cylindrical manner, at least segmentally. The connector may have a receiving opening that receives the rod-like body in at least segmental manner and extends without gaps around its side surface in at least one axial segment. In other words, the contact surface between the connector and the rod-like body may have a closed cylindrical shape, particularly on its side surface.

[0024] Typically, the connector can be attached to the rod only on the side surface of the rod, or only on the end face of the rod, or on both the side and end faces of the rod by surface structures present there (especially molded there).

[0025] For example, a set of local area segments located on a straight or non-straight line extends within an angle range α when viewed from the center of the rod in a cross-sectional view. This angle range α is at most 350°, preferably at most 280°, particularly preferably at most 180°, most preferably at most 90°, and further preferably at most 45°. Because angle α has one of these values, particularly including values ​​up to 45°, the surface structure has only a slight disturbance effect (especially a low-resistance disturbance effect) during the overmolding of the rod when the plastic material is introduced and moved within the gap space partially formed by the rod. Therefore, the overmolding process of the rod can be carried out without significant impact despite the presence of surface structure on the rod. The first set of local area segments arranged on a first straight line and another set of local area segments arranged on another straight line can have a constant spacing. In other words, the first straight line on which the local area segments are arranged can extend equidistantly with at least one other straight line on which the local area segments are subsequently arranged. Preferably, all straight lines extend equidistantly with their adjacent straight lines, each straight line representing the orientation of a local area segment. In this case, a single elongated local region segment can lie on a straight line, or on a group of at least two, preferably at least three, local region segments.

[0026] For example, spaced-apart local sections can be arranged in a row along an extension line (e.g., a straight line), wherein the interval between the first extension line and the adjacent extension line can be at least equal to the maximum extent of the local section transverse to its longitudinal extension line. For example, the extension line can be oriented parallel to the longitudinal axis of the axis.

[0027] The surface structure can be configured such that at least one set of local region segments (particularly at least two sets of local region segments) are arranged spirally or helically in the circumferential direction of the shaft. In other words, the local region segments are helically arranged in one direction along the outer peripheral surface of the rod-like body. For example, to form the helical shape of the local region segments, the rod-like body is rotated during the introduction of protrusions and / or recesses to form a surface structure in its surface segments, particularly during the laser beam action performed for this purpose. It is also possible for the laser beam to rotate around the rod-like body and for the rod-like body to rotate or move relative to the laser beam.

[0028] In an optional method step, a gap space may be formed at least between the rod and the functional device (particularly between the rod and the retainer) before overmolding the rod to form the connector, wherein during overmolding the rod to form the connector, the plastic material for overmolding is introduced into the gap space along the longitudinal axis of the rod via at least one material strand. This at least one material strand is preferably introduced into the gap space such that it moves at least primarily helically or thread-like along the longitudinal axis. This helical or thread-like movement along the longitudinal axis can, for example, have a constant pitch, a constantly varying pitch, or a non-constant pitch. The gap space can, for example, form an annular gap or a gap with a substantially cylindrical sleeve-like basic shape. Preferably, at least two material strands (particularly simultaneously) may be introduced into the gap space along the longitudinal axis of the rod. For example, at least two material strands may be introduced into the gap space through at least two injection ports / injection points of the tooling die, and / or formed by flow settling, thereby forming a material strand geometry within the gap space. Three material lines can also be introduced into the gap space through a flow-guided geometry and / or three injection points, particularly those equidistant from adjacent injection points. The material lines can be introduced, for example, from only one longitudinal side of the rod-like body.

[0029] Before or during the overmolding of a rod-shaped body to form a connector, it is possible to form a gap space at least between the rod-shaped body and the functional device. The plastic material for overmolding is introduced into the gap space from a starting point in a first region (particularly the end region of the surface portion of the rod-shaped body) arranged on the surface portion of the rod-shaped body, and moves within the gap space along the longitudinal direction of the rod-shaped body towards a second region (particularly the end region of the surface portion of the rod-shaped body). The protrusions and / or depressions of the surface structure in the longitudinal section of the first region (particularly the end region) of the rod-shaped body facing the surface portion have a stronger texture than the protrusions and / or depressions of the surface structure in the longitudinal section of the surface portion facing the second region (particularly the end region). Because of the reduction in the texture of the protrusions and / or depressions (i.e., for example, a reduction in their maximum or average height or depth values ​​or roughness values) in the direction of movement of the plastic material moving in the gap space during the overmolding process, consistent and reliable quality can be maintained in the production of multiple components. As the plastic material gradually permeates into the gap space, its resistance fundamentally increases. Therefore, a reduction in resistance relative to the drag effect—resistance arising from the interaction between the plastic material introduced into and moving within the gap space and the surface structure—can be achieved by decreasing the degree of protrusion and / or depression configuration in the flow direction of the plastic material. For example, the gradual infiltration of the plastic material into the gap space leads to a decrease in pressure, resulting in reduced imaging accuracy. This can be compensated for by different configurations of protrusions and / or depressions, particularly by reducing the degree of configuration of protrusions and / or depressions in the flow direction.

[0030] In an optional method step, at least one functional element of the functional device (particularly at least one ladle) may be inserted into a first tool component mold. Furthermore, a cavity is formed by placing at least one second tool component mold on at least one first tool component mold, and the molded functional element (particularly additionally, the molded ladle) is overmolded by filling the cavity with plastic material to form a retainer. After moving at least one second tool component mold to expose a receiving space formed or defined by the retainer, a rod may be inserted into the receiving space. In other words, the rod may be inserted into and / or pass through the exposed portion. The first tool component mold is then closed by the second tool component mold or at least one third tool component mold to form a second cavity at least adjacent to the rod and the retainer, and plastic material is filled into the second cavity to form a connector, thereby at least segmentally overmolding the rod. At least one functional element of the functional device and the optional ladle may preferably be placed, for example, in or on the first tool component mold.

[0031] The plastic materials for the connectors and / or retainers can, for example, be at least segmented (preferably primarily, particularly preferably entirely) from thermoplastics or thermosetting plastics. Thus, epoxy resins and / or phenolic resins can be used as plastic materials, for example. Polyamides (PA), particularly polyphthalamide (PPA) or polyphenylene sulfide (PPS), can also be used as plastic materials for the connectors and / or retainers. For example, this allows for high imaging accuracy during the overmolding process of the rod-shaped body.

[0032] In a preferred embodiment, the magnet can serve as at least one functional element of the functional device. In particular, the rod-shaped body can serve as the shaft of the motor rotor. The connecting body can thus form a hub element connecting the shaft to at least one magnet.

[0033] Typically, a rod-shaped body can be used, for example, as the shaft of a motor rotor. Alternatively, the rod-shaped body can be used, for example, as a bearing element of the stator to support the rotor of the motor (i.e., as the shaft of the rotor).

[0034] An electric coil can be used as at least one functional element of a functional device. In this case, the rod-shaped body connected to the electric coil as a functional device can be used as a shaft supporting a rotor or as a shaft for a motor rotor.

[0035] As at least one functional element of a functional device, a ring-forming body (particularly a closed ring) can be used. Thus, the functional element can be formed, for example, as a bearing sleeve and / or bearing ring and / or a contact element and / or gear forming a valve plate segment. This component can, for example, form a valve, wherein the valve plate is formed by the functional device and a connecting body. In particular, the contact portion of the valve's contact seat can be formed as a functional device in the form of a contact element, which is connected to the rod-like body via the connecting body during the overmolding process. It is also possible that the component produced in the method described herein forms an armature or push rod of a magnetic system. Alternatively or additionally, the rod-like element can be used as a guide rod (particularly for armature systems). Preferably, the component and / or rod-like body and / or functional device and / or connecting body and / or retainer produced by this method can have a rotationally symmetrical shape. For example, the rod-like element can be formed as a single piece from a single metal body, or as multiple pieces from at least two metal bodies. In the case where the rod-shaped element is formed of at least two metal bodies, the at least two metal bodies can be connected to each other by press fitting and / or material bonding and / or shape fitting; preferably, the press fitting and / or material bonding and / or shape fitting of the at least two metal bodies to form the rod-shaped body is performed before or during the process of covering the surface portion of the rod-shaped body with a plastic material forming the connector.

[0036] In addition to the method for manufacturing a component, the present invention also relates to a component having a functional device comprising at least one functional element and a rod-like body, wherein the component is manufactured using the method described herein.

[0037] Furthermore, the present invention relates to an apparatus for manufacturing a component having at least one functional device comprising a functional element and a rod-like body, and manufactured by the method described herein.

[0038] All advantages, details, embodiments and / or features of the components according to the invention can be transferred to or applied to the methods according to the invention and the apparatus according to the invention for producing the components, and vice versa.

[0039] The invention will be explained in more detail with reference to exemplary embodiments shown in the accompanying drawings. The drawings illustrate: Figure 1 This is a schematic diagram of the entire longitudinal section of a component according to an exemplary embodiment.

[0040] Figure 2 It is based on Figure 1 The components in relative to Figure 1 A schematic diagram of the principle of the entire longitudinal section in a section that is rotated about the longitudinal axis.

[0041] Figure 3 It is based on Figure 1 A perspective cross-sectional view of the entire longitudinal section of the component.

[0042] Figure 4 This is a schematic diagram of a rod-shaped body according to an exemplary embodiment.

[0043] Figure 5 It is based on Figure 4 A schematic diagram of the side view of the rod-shaped body.

[0044] Figure 6 It is based on Figure 4 A schematic detail diagram of the surface structure of detail A.

[0045] Figure 7 This is a schematic diagram of a component formed as a valve according to an exemplary embodiment.

[0046] Figure 8 This is a schematic diagram of the surface structure of a rod-shaped body according to an exemplary embodiment.

[0047] Figure 9 This is a schematic diagram illustrating the principle of method steps according to an exemplary embodiment.

[0048] Figure 10 This is a schematic diagram illustrating the principle of method steps according to an exemplary embodiment.

[0049] Figure 11 This is a schematic diagram of a component formed as a stator according to an exemplary embodiment.

[0050] Figure 12 This is a schematic diagram of a gap space, a plastic material introduced into the gap space to cover the molded rod-shaped body, and a pressure distribution, according to an exemplary embodiment.

[0051] Figure 13 This is a schematic diagram of a component formed as a stator according to an exemplary embodiment.

[0052] Figure 14 This is a schematic diagram of a surface structure formed on a circular metal body according to an exemplary embodiment.

[0053] Figure 15 It is based on Figure 14 A schematic end view of a metallic body.

[0054] Figure 16 It is based on Figure 14 A schematic detail diagram of the cross-section of the surface structure, shown in Figure B.

[0055] Figure 17 This is a schematic diagram of a rod-shaped metal body having surface structures on both the end face and the side face, according to an exemplary embodiment.

[0056] Figures 18 to 21 This is a schematic diagram showing the corresponding end face of a rod-shaped metal body having an end face surface structure according to different embodiments.

[0057] Figure 22 This is a schematic diagram of a rod-shaped metal body according to an exemplary embodiment, the metal body having a surface structure only on its end face.

[0058] Figure 23 This is a schematic diagram of a rod-shaped metal body having a surface structure on its end face, according to an exemplary embodiment.

[0059] Figure 24 According to an exemplary embodiment, this is a partial schematic cross-sectional view of a rod-shaped metal body, wherein the cross-sectional plane of the cross-sectional view extends transversely to the longitudinal axis of the rod-shaped metal body.

[0060] Figure 25 This is a schematic diagram of the front view of the surface structure of a rod-shaped metal body according to an exemplary embodiment.

[0061] The accompanying drawings depict a method, or a component 1 produced as a product by the method described herein. This method is used to produce component 1 comprising a functional device 2 and a rod-shaped metal body 3, wherein in one method step, the rod-shaped metal body 3 is provided by setting 100. At the rod-shaped body 3, protrusions and / or recesses are introduced to form a surface structure 4 (introduction 101) at a surface portion 5 of the rod-shaped body 3. Furthermore, using a plastic material forming a connecting body 6, the functional device 2 is provided by setting 102 and the surface portion 5 of the rod-shaped body 3 by overmolding 103, wherein a connection between the rod-shaped body 3 and the functional device 2 is created by overmolding 103 the surface portion 5 of the rod-shaped body 3.

[0062] Before overmolding the surface portion 5 of the rod-shaped body 3 to form the connector 6, the retainer 8 can be at least partially overmolded 104 onto at least one functional element 7, 7' of the functional device 2 using a plastic material. Alternatively or additionally, at least one functional element 7, 7' of the functional device 2 can be a magnetically active element, and during the process of forming the magnetically active element by at least partially overmolding 104 of the retainer 8, an iron slab 9 consisting of at least two iron elements can also be at least partially overmolded. The resulting component 1 can be used, for example, as a rotor of an electric motor.

[0063] like Figure 11 As shown in the example, at least one functional element 7, 7' of the functional device 2 can be an electric coil 40 or include such a coil. In this case, the rod-shaped body 3 connected to the functional device 7, 7' which is an electric coil 40 or includes (i.e., an overmolded) electric coil 40 can serve as a shaft supporting the rotor body 39 of the motor. The surface structure 4 can therefore serve as a tool for forming the connection between the stator body 41 (including the electric coil 40) and the rod-shaped body 3. In the receiving space of the stator body 41, the rotor body 39 (especially the rotor body 39 provided with the bearing portion 38) can be inserted and strung or carried on the rod-shaped body 3 as a shaft (see [reference]). Figure 11 The bearing portion 38 can be formed, for example, as a bearing sleeve.

[0064] according to Figure 13In the illustrated embodiment, at least one functional element 7, 7' can be formed as a coil 40 and is also effectively connected to another functional element of component 1 (particularly to the magnetic flux carrying element of component 1). Thus, for example, this additional functional element can form a housing portion that at least segments surrounds the functional element 7, 7' specifically formed as a coil 40. The other functional element (particularly the functional element 7, 7' serving as the housing of the coil 40) is preferably made of metal. In particular, the additional functional element can be formed in a disc or dish shape. The functional element in contact with the functional element formed as the coil 40, or the additional functional element arranged nearby within component 1, can be a magnetically active element, such that during the intended operation of the coil 40, the additional functional element has conductive or guiding and / or modifying properties with respect to the current magnetic field. This additional functional element can be formed, for example, from an iron ladle 9 as described below.

[0065] At least one functional element 7, 7' of the functional device 2 (particularly all functional elements 7, 7' of the rod-shaped metal body 3 on which the functional device 2 is disposed) and the retainer 8 can be, for example, overmolded with plastic material to form a connector 6, such that the connector 6 contacts or remains in contact with the retainer 8 and at least one functional element 7, 7'. Preferably, the connector 6 remains in contact with the retainer 8, at least one functional element 7, 7', and the metal cladding 9. Therefore, by injection molding the plastic material used to form the connector 6, a tight connection can be created between the retainer 8, at least one functional element 7, 7', and the metal cladding 9.

[0066] The process 101 for introducing protrusions and / or depressions to form surface structures 4 in the rod-shaped body 3 can be performed, for example, by means of at least one laser beam. Surface structures 4 are preferably introduced at locations not covered by plastic material.

[0067] Surface structure 4 can be formed, for example, in the form of multiple local region segments 10, 10', 10”, 11, 11', 11”, wherein the local region segments 10, 10', 10”, 11, 11', 11” are at least segmented (preferably mainly, particularly preferably completely) having a straight orientation. Optionally or additionally, surface structure 4 can be formed in the form of multiple local region segments 10, 10', 10”, 11, 11', 11”, wherein the local region segments 10, 10', 10”, 11, 11', 11” are at least segmented (preferably mainly, particularly preferably completely) having a cross and / or star-shaped structure (see Figure 8 and Figure 14The surface structure 4 may alternatively or additionally be topographically arranged such that the first set of 12 local area segments 10, 10', 10” and at least another set of local area segments 11, 11', 11” are arranged or formed in a row (particularly a straight row). In this case, for example, the first main extension 20 of the first set of local area segments 10, 10', 10” can be equidistant from the other main extension 21 of the other set of 13 local area segments 11, 11', 11”. For example, as Figure 6 As shown, the first group of 12 local region segments 10, 10', 10” can extend on the first line, particularly the first straight line (see main extension line 20), while the second group of 13 local region segments 11, 11', 11” extend on the second line, particularly the second straight line (see main extension line 21), wherein the two lines 20, 21 are equidistant and / or parallel to each other. Figure 6 As shown, the local region segments 10, 10', 10” of the first group 12 and / or the local region segments 11, 11', 11” of the second group 12 can be formed in a wave-like or valley-like manner. Preferably, at least one of the local region segments 10, 10', 10”, 11, 11', 11” is formed as a straight line segment, each straight line segment from a valley point to a mountain point or from a mountain point to a valley point, and accordingly forming a basic waveform. The transition from the first local region segment 10 to the adjacent local region segment 10' can, for example, be guided from the valley point of the first local region segment 10 to the valley point of the adjacent local region segment 10', or from the mountain point of the local region segment 10' to the mountain point of the adjacent local region segment 10”. In general, a waveform formed by mutually spaced local region segments 10, 10', 10”, 11, 11', 11” can be formed accordingly.

[0068] For example, the surface structure 4 can be formed such that at least one set of 12, 13 local region segments 10, 10', 10”, 11, 11', 11”, particularly at least two sets of 12, 13 local region segments 10, 10', 10”, 11, 11', 11” are arranged spirally and / or coiled on the circumference of the rod-shaped body 3. In this case, the local region segments 10, 10', 10”, 11, 11', 11” can be arranged along a surface with a cylindrical or conical basic shape. The spiral or coiled pitch can be constant within the longitudinal direction of the rod-shaped body 3, or can vary in a constant manner, or can be non-constant. For example, Figure 3 , 8 Figures 1 and 14 show the arrangement of local regions 10, 10', and 10" which have a spiral or spiral orientation on the circumference of the rod-shaped body 3.

[0069] like Figure 5As shown, the local region segments 10, 10', 10”, 11, 11', 11” of groups 12 and 13 can be formed within an angle range α. In a cross-sectional view from the center of the rod-shaped body 3, this angle range α is at most 350°, preferably at most 280°, particularly preferably at most 180°, most preferably at most 90°, further preferably at most 45°, and also preferably at most 30°. Because the angle α has at most one of these values ​​(particularly including values ​​up to 45°), when introducing and moving plastic material within the gap space 14 (which is partially formed by the rod-shaped body 3), a slight disturbance effect on the surface structure 4, particularly low resistance, can be achieved during the overmolding of the connector 6. Figure 5 In the diagram, the circumferential range of the local region segments 10, 10', and 10" lies within a small angular range α (e.g., less than 10°). Figure 14 , 15 In the embodiment shown, angle α is equal to 90°, that is, the local area segments 10, 10', 10” allocated to the common group 12 are formed within the angular range formed by angle α.

[0070] Angle β represents the center distance from the first main extension line 20 to the adjacent main extension line 21. Specifically, the angular distance β between adjacent main extension lines 20, 21 is at least 1.5 times, preferably 2.0 times, particularly preferably 2.5 times, and most preferably 3.0 times the maximum unfolding angle value α of the adjacent groups 11, 12 of local region segments 10, 10', 10" ...

[0071] exist Figure 14 and Figure 15 In the embodiment shown, since the four sets of local region segments 10, 10', 10”, 11, 11', 11” of 11 and 12 are evenly spaced on the circumference of the rod-shaped body 3, and each main extension line 20, 21 extends a quarter of the circumference, the angular distance β between adjacent main extension lines 20, 21 is equal to 90°.

[0072] from Figure 14As can be seen, in the region of surface structure 4 or in the region having surface structure 4, the maximum lateral range 42 of the rod 3 can correspond to at least 102%, preferably at least 105%, particularly preferably at least 106.5%, most preferably at least 107.5%, and further preferably at least 110% of the lateral range 43 of the basic shape of the rod 3 or the rod 3 without surface structure 4. Alternatively or additionally, the maximum lateral range 42 of the rod 3 in the region of surface structure 4 or in the region having surface structure 4 can correspond to at most 140%, preferably at most 125%, particularly preferably at most 115%, and further preferably at most 110% of the lateral range 43 of the basic shape of the rod 3 or the rod 3 without surface structure 4. The maximum lateral range 42 of the rod 3 in the region of surface structure 4 is formed by the maximum range transverse to the longitudinal axis 15 of the rod 3, and is therefore formed by the protrusion of surface structure 4. The lateral extent 43 of the basic shape of the rod-shaped body 4 is formed by the lateral extent of the longitudinal axis 15 of the rod-shaped body 3 in the region without the surface structure 4, and is thus formed by the basic shape of the rod-shaped body. Therefore, the lateral extent 43 of the basic shape of the rod-shaped body 4 can form the extent of the rod-shaped body 3, which existed prior to the generation of the laser-assisted surface structure 4. In the case of the cylindrical basic shape of the rod-shaped body 3 before the introduction of the surface structure 4, the lateral extent 42 of its basic shape can correspond to the diameter of the cylinder. For example, the height of the surface structure 4 can be greater than 0.10 mm, preferably greater than 0.20 mm, particularly preferably greater than 0.30 mm, and most preferably greater than 0.35 mm. Alternatively or additionally, the height of the surface structure can be at most 1.00 mm, preferably at most 0.75 mm, particularly preferably at most 0.50 mm, and most preferably at most 0.40 mm.

[0073] Figure 6Exemplary dimensions of the local region segments 10, 10', 10”, 11, 11', 11” are shown. For example, the surface structure 4 can be formed as a plurality of local region segments 10, 10', 10”, 11, 11', 11”, wherein the local region segments 10, 10', 10”, 11, 11', 11” are at least segmentally (preferably primarily, particularly preferably completely) linearly oriented. For example, at least one local region segment 10, 10', 10”, 11, 11', 11”, and especially all local region segments 10, 10', 10”, 11, 11', 11” of the rod-like body 3 can have a width 28 of 0.02 mm to 1.0 mm, preferably 0.05 mm to 0.60 mm, particularly preferably 0.10 mm to 0.40 mm, most preferably 0.15 mm to 0.30 mm, and further preferably 0.20 mm. Alternatively or additionally, at least one local region segment 10, 10', 10”, 11, 11', 11”, particularly all local region segments 10, 10', 10”, 11, 11', 11” of the rod-shaped body 3 may have a length 29 of 0.25 mm to 2.0 mm, preferably 0.35 mm to 1.4 mm, particularly preferably 0.5 mm to 0.9 mm, and most preferably 0.7 mm. The axial spacing 30 between two adjacent local region segments 10, 10', 10”, 11, 11', 11” may, for example, reach 0.05 mm to 1.0 mm, preferably 0.1 mm to 0.6 mm, particularly preferably 0.2 mm to 0.45 mm, and most preferably 0.3 mm.

[0074] Figure 16The local area segments 10, 10', 10”, 11, 11', 11” of the cross shape are shown. The cross shape for surface structure 4 is thus formed by at least two, preferably at least three, and particularly preferably four sub-sections 44, 45, 46, 47. Each sub-section 44, 45, 46, 47 is formed by a laser beam, particularly a straight line. The laser beam is preferably directed towards the center 48 of the cross shape and moves outward from the center 48. This means, for example, that at least two, preferably at least three, and particularly preferably all sub-sections 44, 45, 46, 47 of the cross shape used to form the local area segments 10, 10', 10”, 11, 11', 11” are each formed by a laser beam moving outward from the center 48 of the cross shape. In this case, it may result in the formation of grooves or depressions in the surface of the rod-shaped body 3 at the ends 51 of the sub-sections 44, 45, 46, 47. In other words, at the exit position of the laser used to form sub-parts 44, 45, 46, 47 (see reference numeral 51), recesses may be formed at the respective ends of sub-parts 44, 45, 46, 47. The recesses or ends 51 of sub-parts 44, 45, 46, 47 may be formed at the ends of sub-parts 44, 45, 46, 47 opposite to the center 48. Preferably, at least one sub-part 44, 45, 46, 47 of the cross (preferably all sub-parts 44, 45, 46, 47) may have an elongated orientation, and the width of the cross is in the range of 0.05 mm to 0.5 mm, preferably in the range of 0.07 mm to 0.40 mm, and particularly preferably in the range of 0.9 mm to 0.20 mm. At least one sub-part 44 may, for example, form a 90° angle with at least one adjacent sub-part 45 relative to its main extension line.

[0075] The maximum range 50 of the cross-shaped sub-parts 44, 45, 46, 47 can, for example, be between 0.10 mm and 5.0 mm, preferably between 0.20 mm and 2.0 mm, particularly preferably between 0.25 mm and 1.5 mm, further preferably between 0.30 mm and 1.2 mm, most preferably between 0.5 mm and 1.0 mm, and further preferably between 0.6 mm and 0.80 mm.

[0076] Specifically, the values ​​of width 28 and / or length 29 and / or axial spacing 30 are applicable to rod-shaped bodies 3 with a cross-sectional range of 4 mm to 20 mm, preferably 4.5 mm to 10 mm, and particularly preferably 5.0 mm to 7.5 mm.

[0077] Prior to the overmolding process 103 for forming the rod 3 of the connector 6, a gap space 14 may be formed, for example, at least between the rod 3 and the functional device 2, and particularly at least between the rod 3 and the retainer 8, wherein during the overmolding process 103 for forming the rod 3 of the connector 6, the plastic material for overmolding is introduced into the gap space 14 via at least two material lines along the longitudinal axis 15 of the rod 3. The material lines represent the plastic material introduced into the gap space 14 and unfolded there. Preferably, at least two material lines are introduced into the gap space 14 such that they move at least primarily helically and / or spirally along the longitudinal axis 15. It can prove advantageous if the material lines unfold in a direction and / or orientation path around the longitudinal axis 15 of the rod 3 corresponding to or similar to the local region segments 10, 10', 10”, 11, 11', 11” of the surface structure 4. Therefore, the surface structure 4 or its local regions 10, 10', 10”, 11, 11', 11” can have a dual function: on the one hand, they increase the connection strength between the rod-shaped body 3 and the connector 6; on the other hand, they can guide the plastic material during the overmolding of the rod-shaped body. The plastic material guiding function preferably ensures that the local regions 10, 10', 10”, 11, 11', 11” generate as little resistance as possible to the introduced plastic material.

[0078] like Figure 12 As shown in the example, a gap space 14 may be formed at least between the rod-shaped body 3 and the functional device 2 before or during the overmolding 103 for forming the connecting body 6. The plastic material for the overmolding 103 is introduced into the gap space 14 from a starting point located in a first region 16 (particularly the end region) of the surface portion 5 of the rod-shaped body 3, which has a surface structure 4, and moves within the gap space 14 along the longitudinal direction of the surface portion 5 of the rod-shaped body 3 toward a second region 17 (particularly the end region) of the rod-shaped body 3. The protrusions and / or recesses of the surface structure 4 at the longitudinal section 18 of the surface portion 5 facing the first region 16 (particularly the end region) have a stronger construction than the protrusions and / or recesses of the surface structure 4 at the longitudinal section 19 of the surface portion 5 facing the second region 17 (particularly the end region). In other words, within the gap space 14 along the longitudinal range of the rod-shaped body 3 or along the longitudinal range of the surface structure 4 of the rod-shaped body 3, the plasticized plastic material moves from the starting point 35 (e.g., the first region 16) to the ending point 36 (e.g., the second region 17). The pressure drop caused by the gradual penetration of the plastic material into the gap space in this case can be compensated by reducing the construction of bulges and / or depressions in the surface structure 4 occurring in the flow direction 37. Figure 12 The lower half illustrates this pressure distribution in plastic materials by way of example. Furthermore, in Figure 12In the embodiment shown, at the starting point 35, the local region segments 10, 10', 11, 11' of the surface structure 4, which is formed into a cross structure, are formed or configured to be larger than at the ending point 36.

[0079] An advantageous method may include inserting at least one functional element 7, 7' of the functional device 2 into a first tool component mold 105, particularly inserting at least one ladle 9 into the first tool component mold; and overmolding the functional elements 7, 7' (particularly additionally overmolding the ladle 9) 104 by placing at least one second tool component mold onto at least one first tool component mold to form a cavity 106, and by filling the cavity 31 with plastic material for forming the retainer 8. Furthermore, at least one second tool component mold is moved 107 to expose a receiving space 32 defined by the retainer 8; and a rod 3 is inserted 108 into the receiving space such that the rod 33 is received in the receiving space. The first tool component mold is then closed 109 by the second tool component mold or by at least one third tool component mold to form a second cavity 34 at least adjacent to the rod 3 and the retainer 8, and the rod 3 is overmolded at least segmentally 103 by filling the second cavity with plastic material for forming the connector 6.

[0080] The plastic material of the connector 6 and / or the plastic material of the retainer 8 may, for example, be formed at least segmentally (especially entirely) from thermoplastic or thermosetting plastic.

[0081] The component 1 produced in the method described herein may, for example, include at least one functional element 7, 7' of the functional device 2, which is a magnetically active element, i.e., the functional element 7, 7' may have permanent magnet characteristics or magnetizable characteristics or at least the characteristic of temporarily generating a magnetic field. For example, the magnetically active element is an electric coil that can be excited, particularly by copper wire. The rod-shaped body 3 may, for example, be used as the rotor shaft of an electric motor (not shown), such as (a1) a DC motor or (a2) an AC and three-phase motor and / or (b1) a rotating magnetic field and moving magnetic field motor or (b2) a commutator motor. In particular, the motor in which the component 1 produced by the method described herein is used as the rotor may be a (three-phase) asynchronous motor or a (three-phase) synchronous motor with a permanent or external excitation design.

[0082] Alternatively or additionally, at least one functional element 7, 7' of component 1 may be formed as the body of a forming ring, particularly as the body of a closed ring. Specifically, at least one functional element 7, 7' may be formed as a bearing sleeve and / or a bearing ring and / or a contact element 25 forming a valve plate section, or as a component of the aforementioned elements. As an example, Figure 7The component 1 formed as valve 22 is shown, wherein the valve stem 23 of valve 22 is formed at least segmentally (preferably primarily, particularly preferably completely) of rod-shaped metal body 3, and the valve plate 24 of valve 22 is formed at least segmentally (preferably primarily) of connecting body 6. At least one functional element 7, 7' may be formed as at least one contact element 25 of valve 22, which serves as the contact portion of valve 22 relative to valve seat ring 26 during intended operation. The contact element 25 may be formed as an annular or sleeve-shaped body.

[0083] It is possible that the surface structure 4 is specifically formed on the end face 52 of the rod-shaped metal body 3 (see...). Figure 22 This allows the overmolded part (i.e., the connector 6) at the end of the rod-shaped body 3 to form an extension of the rod-shaped body 3. Optionally, the outer surface of the rod-shaped body 3 can be flush with the connector 6 that abuts the end face of the rod-shaped body 3. The surfaces of the rod-shaped body 3 and / or the adjacent connector 6 can, for example, serve as bearing surfaces for a body 3 (e.g., a rotor) supported on that surface. In other words, by molding the end face of the connector 6 formed of plastic, the extension of the metal rod-shaped body 3 can serve as an axial fixing and / or restraining element for an element (e.g., a rotor) movably supported on the rod-shaped body 3, which serves as a shaft.

[0084] Optionally, the surface structure 4 may be formed, for example, on the end face 52, and additionally on the side surface 53 of the rod-shaped metal body 3 (see...). Figure 17 For example, in Figure 1 The image shows the fixing of the connector 6 to the rod-shaped body 3, which is only located on the side surface 53.

[0085] For example, surface structure 4 can be formed as at least one uninterrupted or interrupted line, particularly a straight line. For example, surface structure 4 can be formed as a radially extending dashed or dotted line, particularly a dashed or dotted line (see...). Figure 18 Alternatively or additionally, the star-shaped and / or cross-shaped sub-parts of surface structure 4 may be formed on end face 52. For example, the star-shaped and / or cross-shaped sub-parts may be located on a circular line concentric with the center (see...). Figure 19 ).according to Figure 20 In the alternative embodiment shown, the annular portion of end face 52 may have surface structure 4, or the central region 61 may not have surface structure 4. For example, as Figure 21 As shown, surface structure 4 can be formed in a fan shape, especially an annular fan shape.

[0086] It is possible that, at the connecting section 53 of the connector 6, the base 54, movably supported on (particularly in or on) the rod 3, is connected via a mating connecting section 55 on the base side, such that due to the interaction of the connecting section 53 and the mating connecting section 55, the base 54 has at least limited mobility (which may also include immobility) relative to the rod 3 in at least one direction (particularly in two directions). For example, limited mobility may exist when axial mobility is made possible by mechanical clearance (e.g., less than 10 mm, preferably less than 5 mm, particularly preferably less than 2 mm, particularly preferably less than 1.0 mm). Preferably, the mobility of the base 54 relative to the connector 6 is restricted or prevented in both axial directions. For example, the limited mobility of the base 54 relative to the rod 6 may also include complete prevention of mobility along the longitudinal axis of the rod 3.

[0087] Preferably, the base 54 may include a predetermined bending region 59, such that the segment 57 having the mating connecting segment 55 can be bent 60 relative to the support segment 58 that ensures support relative to the rod 3, particularly performing an elastic bending motion. For example, during the assembly of the base 54 and the rod 3 and / or the base 54 and the connecting segment 53 (particularly by axial movement), the segment 57 undergoes a brief deflection relative to the support segment 58. In other words, the connection formed by the connecting segment 53 and the mating connecting segment 55 can form a snap-fit ​​connection or a form-fit connection. Preferably, the connection formed by the connecting segment 53 and the mating connecting segment 55 is formed (particularly specifically formed) such that it can rotate about the longitudinal axis of the rod 3. For example, the base 54 can form a rotor, particularly a rotor of an electric motor. Optionally, a bearing assembly 56 can be arranged between the rod 3 and the base 54. Preferably, the bearing assembly 56 is a rolling bearing (e.g., a ball bearing and / or a roller bearing) or is formed as a sliding bearing.

[0088] Figure 24A cross-section of a rod-shaped body 3 having surface structure 4 is shown. In this case, at least one affected region 67 (preferably all affected regions 67) formed by at least one depression during the laser-assisted introduction (101) process can have: (a) a depth 62 of at least 200 micrometers, preferably at least 600 micrometers, particularly preferably at least 800 micrometers, particularly preferably at least 1000 micrometers, most preferably at least 1200 micrometers, and / or (b) a depth 62 in the range of 50 micrometers to 5000 micrometers, preferably 100 micrometers to 4000 micrometers, particularly preferably 200 micrometers to 3500 micrometers, further preferably 300 micrometers to 2500 micrometers, and / or (c) a depth 62 of up to 5000 micrometers, preferably 4000 micrometers, particularly preferably 3500 micrometers, further preferably 3000 micrometers, most preferably 2500 micrometers. The affected region is understood to be the region of the rod-shaped body formed due to the laser-assisted formation of the depression, particularly the region adjacent to the depression. In other words, the laser beam causes a change in the structure and / or density of the rod-shaped body 3. In this case, the laser acting on the rod 3 causes a region-dependent change in the material structure and / or density of the rod 3, thereby forming an affected region 67. Depth 62 is measured from the bottom surface of the rod 3. Optionally, the protrusions of the surface structure 4 may have: (a) a height 63 of at least 50 micrometers, preferably 100 micrometers, particularly preferably 200 micrometers, further preferably 250 micrometers, and most preferably 300 micrometers; and / or (b) a height 63 in the range of 50 micrometers to 1500 micrometers, preferably 100 micrometers to 1250 micrometers, particularly preferably 200 micrometers to 1000 micrometers, further preferably 250 micrometers to 800 micrometers, and most preferably 300 micrometers to 600 micrometers; and / or (c) a height 63 of up to 1500 micrometers, preferably 1250 micrometers, particularly preferably 1000 micrometers, further preferably 800 micrometers, and most preferably 600 micrometers. Height 63 can be measured, for example, from the bottom surface of the rod 3 (see...). Figure 24 The aforementioned minimum and / or maximum and / or ranges are particularly applicable to rod-shaped bodies 3 with diameters ranging from 4,000 mm to 10,000 mm, preferably from 5,000 mm to 8,000 mm, and especially preferably from 5,000 mm to 7,000 mm.

[0089] Alternatively or additionally, the ratio of the height 63 of at least one protrusion of surface structure 4 to the depth 62 of at least one (particularly during laser-assisted introduction of the recess 101, forming on the rod body with density variation and adjacent to at least one protrusion) influence region 67 can be in the range of 0.05 to 0.75, preferably 0.075 to 0.60, particularly preferably 0.10 to 0.50, further preferably 0.125 to 0.4, and most preferably 0.10 to 0.35. In a particularly advantageous variant embodiment, this ratio can be in the range of 0.20 to 0.35, particularly in the range of 0.25 to 0.30. For example, the above ratio applies to most (particularly all) of the protrusions and influence regions allocated to the corresponding recesses of surface structure 4. By using the ratio of depth 62 to height 63 (particularly the ratio of influence regions of adjacent recesses and protrusions), the material redistributed on the base surface of rod body 3 to form protrusions is achieved by removing material from the base of rod body 3 in a manner that is both small in cross-section and deep. By means of laser bombardment of the rod-shaped body 3, conical or truncated conical recesses and / or porous structures can be formed on the rod-shaped body 3, and thereby (especially those located at deeper depths), material of the rod-shaped body 3 is "carried out" and provided as protrusions of the surface structure 4 (see Figure 24 ).

[0090] Possibly, at least one affected region 67, formed as a region with density variation on the rod-shaped body 3 during the laser-assisted introduction of at least one recess 101, has a depth 62 to width 64 ratio in the range of 2 to 15, preferably 4 to 10, particularly preferably 5 to 9. Preferably, at least one affected region 67 has a basic conical or truncated conical shape. The affected region can be understood as the region heat-treated during the laser action used to form the surface structure.

[0091] Alternatively or additionally, the recess may have a depth 62, which has a ratio relative to the diameter 65 of the rod 3 in the range of 0.05 to 0.34, preferably 0.075 to 0.30, particularly preferably 0.10 to 0.25, further preferably 0.15 to 0.25, and most preferably 0.175 to 0.25. The above depth values ​​relate to the depth of the recess.

[0092] In an optional exemplary embodiment, at least one protrusion of the surface structure 4 has a height 63, which has a ratio relative to the diameter 65 of the rod-shaped body 3 in the range of 0.010 to 0.300, preferably 0.015 to 0.250, particularly preferably 0.020 to 0.170, further preferably 0.030 to 0.170, most preferably 0.035 to 0.140, and further preferably 0.040 to 0.100.

[0093] In addition to this method, the present invention also relates to a component 1 having a functional device 2 comprising at least one functional element 7, 7' and a rod-like body 3, and the component 1 being manufactured in the method described herein. Finally, the present invention relates to an apparatus for manufacturing a component 1 having at least one functional device 2 comprising functional elements 7, 7' and a rod-like body 3. This apparatus performs the method for manufacturing the component 1 described herein.

[0094] List of reference numerals 1 component; 2. Functional devices; 3 rods; 4. Surface structure; 53 surface cross section; 6 connectors; 7. Functional elements of 7'2; 8. Maintain body; 9 iron bags; 10, 10', 10” local area section; 11, 11', 11" local area section; 12 First group 10, 10', 10”; 13 Another set of 11, 11', 11”; The gap between 142 and 3; The vertical axis is 153; The first area is 165; The second area of ​​175; The first longitudinal section of 185; The second longitudinal section of 195; The main extension line of 2012; The main extension line of 2113; 22 valves; Valve stem of 2322; Valve plate of 2422; 2522 contact elements; 26 Valve seat ring; 27. Intermediate space; Width of 2810; The length is 2910; The spacing between 3010 and 10'; 31. First cavity; 32. Exposed receiving space; 33 received in the receiving space; 34. Second cavity; 35 starting point; 36. Finish line; 37. Flow direction; The bearing portion of 3839; 39 rotor body; 40 coils; 41. Stator body; 42 has a maximum lateral range of 3 out of 4; 43 has no maximum lateral range of 3 compared to 4; 44 sub-parts; 45 sub-parts; 46 sub-parts; 47 sub-parts; 48 centers; Widths of 4944, 45, 46, and 47; The maximum range within which 5044, 45, 46, and 47 form a cross; 5144, 45, 46, 47 end 523 end face; 536 connecting section; 54 matrix; 5554's paired connection segment; 56 bearing assembly; Section 5754; Support section 5854; 5954's predetermined bending area 60° bending motion; The central area of ​​6152; 62. Depth of the depression; The height of the 63 protrusions; 64. Width of the recessed groove; The diameter is 653; The side view of 663; The area affected by 673; 100 provides 3; 101 introduces 4; 102 provides 2; 103 is used to form the overmolding of 6; 104 is used for overmolding to form 8; Insert 7' and 7' at 105; 106 formed; 107 moves; Insert 3 into 108.

Claims

1. A method for manufacturing a component (1) comprising a rod-shaped metal body (3), the method comprising the following steps: Set (100) rod-shaped metal body (3); (101) Protrusions and / or depressions are introduced to form a surface structure (4) on the surface portion (5) of the rod (3). The surface portion (5) of the rod-shaped body (3) is overmolded (103) with plastic material used to form the connector (6), wherein the connection between the rod-shaped body (3) and the connector (6) is created by overmolding (103) the surface portion (5) of the rod-shaped body (3).

2. The method according to claim 1, characterized in that, The method includes setting (102) a functional device (2), wherein a connection between the rod (3) and the functional device (2) is created by overmolding (103) the surface portion (5) of the rod (3).

3. The method according to claim 2, characterized in that, The functional device (2) includes at least one functional element (7, 7'), which is a magnetically active element; preferably, at least one functional element (7, 7') is used, which is a magnet, a magnetizable element or an element that affects the magnetic field.

4. The method according to claim 3, characterized in that, The component (1) is used as a component of the motor, and in particular, the component is used as the stator or rotor or magnetic coil of the motor.

5. The method according to any one of claims 2 to 4, characterized in that, Before the surface portion (5) of the rod-shaped body (3) is overmolded (103) to form the connector (6), during the joining process, the retainer (8) is fastened to at least one functional element (7, 7') of the functional device (2); in particular, the retainer (8) is molded thereon by at least partial overmolding (104) of a plastic material.

6. The method according to any one of claims 2 to 5, characterized in that, At least one functional element (7, 7') of the functional device (2) is a magnetically active element, and during the engagement of the retainer (8) to the functional element (7, 7'), particularly during the process of at least partially covering the magnetically active element (104) to form the retainer (8), the iron bag (9) consisting of at least two iron elements is also at least partially covered.

7. The method according to claim 5 or 6, characterized in that, The at least one functional element (7, 7'), in particular all the functional elements (7, 7') of the rod-shaped metal body (3) provided with the functional device (2), and the retainer (8) formed by covering the plastic material to form the connector (6), such that the connector (6) remains in contact with the retainer (8) and the at least one functional element (7, 7'); preferably, the connector (6) remains in contact with the retainer (8), the at least one functional element (7, 7') and the iron cladding (9).

8. The method according to any one of the preceding claims, characterized in that, By means of at least one laser beam, protrusions and / or depressions are introduced (101) to form the surface structure (4) in the rod-shaped body (3).

9. The method according to any one of the preceding claims, characterized in that, The surface structure (4) is formed in the form of multiple local region segments (10, 10', 10”, 11, 11', 11”), wherein the local region segments (10, 10', 10”, 11, 11', 11”) are at least segmented, preferably mainly, and particularly preferably completely linear.

10. The method according to any one of the preceding claims, characterized in that, The surface structure (4) is formed in the form of multiple local area segments (10, 10', 10”, 11, 11', 11”), wherein the local area segments (10, 10', 10”, 11, 11', 11”) have at least segmented, preferably mainly, particularly preferably completely cross and / or star-shaped structures, especially when viewed in a top view.

11. The method according to claim 9 or 10, characterized in that, The surface structure (4) is formed such that the first group 12) local region segments (10, 10', 10”, 11, 11', 11”) and at least another group of local region segments (10, 10', 10”, 11, 11’, 11”) each form a row, in particular, each form a straight row; preferably, the first longitudinal extension of the first group of local region segments (10, 10', 10”, 11, 11’, 11”) is equidistant from the other longitudinal extension of the other group 13) local region segments (10, 10', 10”, 11, 11’, 11”).

12. The method according to any one of claims 9 to 11, characterized in that, The surface structure (4) is formed such that at least one set of local region segments (10, 10', 10”, 11, 11', 11”), and in particular at least two sets of local region segments (10, 10', 10”, 11, 11', 11”) are spirally arranged and / or coiled around the circumference of the rod-shaped body (3).

13. The method according to any one of claims 2 to 12, characterized in that, Before overmolding (103) the rod (3) to form the connector (6), a gap space (14) is formed at least between the rod (3) and the functional device (2), and particularly at least between the rod (3) and the retainer (8), wherein, during overmolding (103) the rod (3) to form the connector (6), plastic material for overmolding is introduced into the gap space (14) via at least one material line along the longitudinal axis (15) of the rod (3); preferably, the at least one material line is introduced and / or guided into the gap space (14) such that it moves spirally and / or spirally at least primarily along the longitudinal axis (15).

14. The method according to any one of claims 2 to 13, characterized in that, Before or during the overmolding (103) of the rod (3) to form the connector (6), a gap space (14) is formed at least between the rod (3) and the functional device (2), wherein the plastic material for overmolding (103) is introduced into the gap space (14) from the starting point of a first region (16) of the surface portion (5) of the rod (3) having a surface structure (4), particularly from the starting point of the end region of the surface portion (5) of the rod (3) having a surface structure (4), and within the gap space (14) Moving along the longitudinal range of the rod (3) toward the second region (17) of the surface portion (5) of the rod (3) having surface structure (4), particularly the end region of the surface portion (5) of the rod (3) having surface structure (4), wherein the protrusions and / or depressions of the surface structure (4) at the longitudinal segment (18) of the rod (3) facing the first region (16) have a stronger structure than the protrusions and / or depressions of the surface structure (4) at the longitudinal segment (19) of the rod (3) facing the second region (17).

15. The method according to any one of claims 2 to 14, characterized in that: Insert (105) at least one functional element (7, 7') of the functional device (2), particularly at least one iron slab (9), into the first tool component mold; The cavity (106) is formed by placing at least one second tool component mold on the at least one first tool component mold, and the cavity is filled with plastic material for forming the retainer (8) to overmold (104) the functional elements (7, 7'), and in particular, to additionally overmold the iron bag (9). Move (107) the at least one second tool component mold to expose the receiving space defined by the retainer (8); Insert the rod-shaped body (3) into the receiving space (108); The first tool component mold is closed (109) by the second tool component mold or by at least one third tool component mold to form a second cavity at least adjacent to the rod (3) and the retainer (8), and the rod (3) is at least segmentally overmolded (103) by filling the second cavity with plastic material to form the connector (6).

16. The method according to any one of the preceding claims, characterized in that, The plastic material of the connector (6) and / or the plastic material of the retainer (8) are at least segmentally, and in particular entirely, made of thermoplastic or thermosetting plastic.

17. The method according to any one of the preceding claims, characterized in that, The rod-shaped body (3) Used as a shaft for motor rotor, or A bearing element used as a stator to support the rotor of the motor.

18. The method according to any one of claims 2 to 17, characterized in that, Using an electric coil as at least one functional element (7, 7') of the functional device (2).

19. The method according to any one of claims 2 to 18, characterized in that, The forming ring, especially the body forming the closed ring, is used as the at least one functional element (7, 7'); in particular, the bearing sleeve and / or bearing ring and / or contact element forming the valve plate section is used as the functional element (7, 7').

20. The method according to any one of the preceding claims, characterized in that, The surface structure (4) is formed, in particular, specifically formed on the end face (52) of the rod-shaped metal body (3).

21. The method according to any one of the preceding claims, characterized in that, At the connecting section (53) of the connector (6), a base (54) movably supported on the rod (3), particularly in or on the rod (3), is connected via its mating connecting section (55), such that due to the interaction between the connecting section (53) and the mating connecting section (55), the base (54) has at least limited mobility relative to the rod (3) in at least one axial direction, particularly in two axial directions.

22. The method according to any one of the preceding claims, characterized in that, During the process of laser-assisted introduction (101) of at least one depression, an influence region (67) with density variation is formed or can be formed on the rod-shaped body (3), wherein the influence region (67) Having a depth (62) of at least 200 micrometers, preferably at least 600 micrometers, particularly preferably at least 800 micrometers, particularly preferably at least 1000 micrometers, and most preferably at least 1200 micrometers, and / or Having a depth (62) of 50 micrometers to 5000 micrometers, preferably 100 micrometers to 4000 micrometers, particularly preferably 200 micrometers to 3500 micrometers, and even more preferably 300 micrometers to 2500 micrometers, and / or It has a depth of up to 5000 micrometers, preferably 4000 micrometers, particularly preferably 3500 micrometers, further preferably 3000 micrometers, and most preferably 2500 micrometers (62).

23. The method according to any one of the preceding claims, characterized in that, The protrusions of the surface structure (4) Having a height of at least 50 micrometers, preferably 100 micrometers, particularly preferably 200 micrometers, further preferably 250 micrometers, and most preferably 300 micrometers (63), and / or Having a height (63) of 50 micrometers to 1500 micrometers, preferably 100 micrometers to 1250 micrometers, particularly preferably 200 micrometers to 1000 micrometers, further preferably 250 micrometers to 800 micrometers, and most preferably 300 micrometers to 600 micrometers, and / or It has a height of up to 1500 micrometers, preferably 1250 micrometers, particularly preferably 1000 micrometers, further preferably 800 micrometers, and most preferably 600 micrometers (63).

24. The method according to any one of the preceding claims, characterized in that, The ratio of the height (63) of at least one protrusion of the surface structure (4) to the depth (62) of at least one affected area (67) is in the range of 0.05 to 0.75, preferably in the range of 0.075 to 0.60, particularly preferably in the range of 0.10 to 0.50, more preferably in the range of 0.125 to 0.4, and most preferably in the range of 0.10 to 0.

35. The at least one affected area (67) is particularly adjacent to the protrusion and is formed as a region with density variation on the rod-shaped body (3) during the laser-assisted introduction (101) recess.

25. The method according to any one of the preceding claims, characterized in that, During the process of laser-assisted introduction (101) of at least one recess, at least one influence region (67) forming on the rod-shaped body (3) having a density variation region has a depth (62) width (64) ratio in the range of 2 to 15, preferably 4 to 10, particularly preferably 5 to 9; preferably, the at least one influence region (67) has a basic shape of a cone or a truncated cone.

26. The method according to any one of the preceding claims, characterized in that, The influence region (67) formed during the laser-assisted introduction (101) of the recess into the rod has a depth (62) relative to the diameter (65) of the rod (3) in the range of 0.05 to 0.34, preferably 0.075 to 0.30, particularly preferably 0.10 to 0.25, further preferably 0.15 to 0.25, and most preferably 0.175 to 0.

25.

27. The method according to any one of the preceding claims, characterized in that, At least one protrusion of the surface structure (4) has a height (63) which has a ratio to the diameter (65) of the rod (3) in the range of 0.010 to 0.300, preferably 0.015 to 0.250, particularly preferably 0.020 to 0.170, further preferably 0.030 to 0.170, most preferably 0.035 to 0.140, and further preferably 0.040 to 0.

100.

28. A component (1) comprising a rod-shaped body (3), said component (1) being manufactured by a method according to any one of the preceding claims.

29. An apparatus for producing a component (1) comprising at least one rod-shaped body (3) by the method according to any one of claims 1 to 27.

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