Method for producing a finished component comprising an electronic element

Abstract

Method (100) for manufacturing a finished component (15) comprising an electronic element (13), wherein the method (100) comprises the injection (105) of a coating material (12) and the coating (106) of the electronic element (13) to produce (108) a protection of the electronic element (13) and to simultaneously generate (109) a final geometry of the finished component (15), characterized by the fact that for the injection (105) and the coating (106) no injection molding process is used, wherein the process is a low-pressure plastic casting process, wherein the process (100) uses a processing temperature of at most 200°C and an internal tool pressure of at most 70 bar, the process does not include any further step to produce a desired final geometry of the component, wherein the coating mass (12) is a reactive thermoplastic mass, namely a low viscosity matrix system, wherein the coating mass (12) comprises caprolactam, wherein the method (100) comprises inserting and positioning (102a) the electronic element (13) into a temperature-controlled tool (10), wherein the method comprises inserting and positioning (103) a textile reinforcement element (14), namely an endless fiber reinforced semi-finished product, into the tempered tool (10).

Description

[0001] The invention relates to a method for manufacturing a finished component comprising an electronic element according to claim 1. State of the art

[0002] Integrating sensors and lighting elements into plastic components is hardly possible with established methods such as plastic injection molding, as high pressure and temperatures can damage the components. Therefore, current technology relies on retrofitting sensors and lighting elements into plastic components. Integrating sensors and lighting elements into fiber composite manufacturing processes is possible because these processes involve lower pressures and temperatures. However, these processes are very labor-intensive and involve long cycle times, for example, with autoclave curing of prepreg or hand lamination.

[0003] US 2015 / 0 366 076 A1 relates to a method for encasing an electronic component using a foamed thermoplastic.

[0004] DE 695 09 739 T2 discloses a method for encapsulating an electronic component and an electronic component encapsulated by this method.

[0005] US 2016 / 0185088 A1 discloses a composite comprising a resin and a metal.

[0006] US 2016 / 0052234 A1 discloses a fabric comprising a thermoplastic resin component.

[0007] EP 2 338 665 A1 relates to a method and an apparatus for polymerizing lactams in molds. Description of the invention: Problem, solution, advantages

[0008] The object of the present invention is to improve a method for manufacturing a finished component comprising an electronic element in such a way that direct integration of the electronic element into the component is achieved. Furthermore, manufacturing and assembly costs as well as material requirements are to be reduced.

[0009] The above-mentioned problem is solved by a method for manufacturing a finished component comprising an electronic element, which includes the injection of a coating material and the encasing of the electronic element to provide protection for the electronic element and to simultaneously generate a final geometry of the finished component.

[0010] The term "component" refers to a structural component that primarily exhibits a planar geometry. In particular, the process is used to manufacture a finished component for a vehicle, such as a floor assembly, a tailgate, or a bumper, or an interior part, such as a strut, a mirror, or a door panel. Furthermore, the process can be used to manufacture components for the aerospace, mechanical engineering, sports, or gaming industries.

[0011] The term "finished component" refers specifically to the fact that the process does not include any further, subsequent injection step to create the component's geometry. The finished component can be, in particular, a structural component or a basic structure. A basic structure is understood to be a structure that is mounted onto another component, especially a structural component, without any injection or coating step taking place. Mounting onto another component can be achieved, in particular, by joining processes such as welding or by creating a detachable connection, for example, using clips.

[0012] The term "final geometry" primarily means that the process does not include any further steps to produce the desired final geometry of the component. Specifically, the process is used to create paintable and / or colored and / or translucent surfaces, resulting in a finished component characterized by these features. Furthermore, the process does not include any additional manufacturing steps for producing the aforementioned surfaces, such as grinding operations, on the final component.

[0013] The term "injection" preferably refers to pressing the material into the interior of a tool. The term "encapsulation" primarily refers to the complete flow of the encapsulation material around the electronic component, so that the component is completely enclosed by the material. Advantageously, the electronic component is flooded with the encapsulation material during the injection and encapsulation step. This protects the electronic component from external influences, particularly high pressures or temperatures, while simultaneously creating the final geometry of the finished component. According to the invention, the injection and encapsulation step does not employ an injection molding process. In particular, the entire process does not include any step that utilizes injection molding.

[0014] An "electronic element" primarily refers to a sensor and / or light element. The process is specifically a method for functionalizing the component. Advantageously, the process can involve inserting more than one electronic element, which is then encased in the coating material in a single step, thus functionalizing the finished component with multiple electronic elements.

[0015] The inventive method enables the production of finished components using less material compared to conventional assembly solutions. This gives the inventive method potential for lightweight construction. Furthermore, the number of individual components and joining elements is reduced, thereby saving costs. Subsequent assembly effort, and consequently time and costs, are also reduced. In addition, the excellent embedding of the electronic element within the finished component, achieved through the encapsulation, eliminates the need for sealing measures or additional protection against aggressive media, such as corrosion protection. The method is also suitable for producing paintable surfaces, again saving time and costs during painting and paint preparation.

[0016] According to the invention, the method uses a processing temperature of at most 200°C, more preferably at most 180°C, and more preferably at most 160°C. In particular, the processing temperature is approximately 150°C. The processing temperature is primarily the temperature at which the injection of the coating material and the coating of the electronic element take place. In particular, the method uses a temperature-controlled tool that is brought to the aforementioned temperature. According to the invention, the method uses an internal tool pressure of at most 70 bar. In particular, the method uses an internal tool pressure of 1 bar to 60 bar, more preferably 2.5 bar to 55 bar, and more particularly 5 bar to 50 bar. This enables the use of lower processing temperatures and significantly reduced internal tool pressures compared to established manufacturing processes.

[0017] The coating material is a thermoplastic. It is a reactive thermoplastic material that is injected into the interior of the temperature-controlled mold. The finished component is therefore preferably a thermoplastic component including an electronic element. According to the invention, the method for manufacturing the finished component is a low-pressure plastic casting process.

[0018] The coating material is primarily a low-viscosity matrix system. According to the invention, the coating material comprises caprolactam. The coating material consists primarily of caprolactam.

[0019] The coating material exhibits primarily elastic and soft properties, which are particularly useful for creating "soft-touch surfaces." Furthermore, it enables the creation of tribologically optimized properties for highly stressed surfaces of the finished component. In particular, the process does not include any further injection steps, especially after embedding, i.e., encapsulating the electronic element. Therefore, all subsequent manufacturing steps are neither injection-based nor coating-based.

[0020] According to the invention, the method comprises inserting the electronic element into the temperature-controlled tool and positioning the electronic element within the temperature-controlled tool. The electronic element can be fixed in the tool by means of magnetic holders and / or clamps.

[0021] The electronic component, either on its own or together with a holding element, can be inserted into the tool. The holding element can include fasteners, such as holders, for securing the electronic component, which may be reinforced with short fibers if required. The method can include manufacturing this holding element, preferably by injection molding or low-pressure plastic casting. Furthermore, the method can include attaching and / or positioning the electronic component to the holding element. The holding element, equipped with the electronic component, is then inserted into the tool and encased with the coating material.

[0022] According to the invention, the method can include inserting a textile reinforcement element into the temperature-controlled tool and positioning the textile reinforcement element in the tool before injecting the coating material. The textile reinforcement element serves to mechanically reinforce the finished component. In particular, it is a planar, textile reinforcement element. The textile reinforcement element is impregnated during the injection of the coating material. According to the invention, the textile reinforcement element is a continuous fiber-reinforced semi-finished product. The method can further include inserting and positioning several reinforcement elements. The method thus enables the parallel integration of electronic components and reinforcement structures.

[0023] Furthermore, the process can include the curing, or in other words, solidification, of the coating material, which preferably takes place within the temperature-controlled tool. Only after curing is the finished component removed from the tool.

[0024] The process can be used to produce a basic structure that includes the electronic element and can therefore be regarded as a finished component that is subsequently mounted on another component. Brief description of the drawings

[0025] They show schematically: Fig. 1 a process scheme of a process according to the invention; and Fig. 2a to 2d Cross-sections of a temperature-controlled tool for carrying out the method according to the invention Fig. 1 after various procedural steps. Preferred embodiments of the invention

[0026] Fig. Figure 1 shows a process scheme of a method (100) according to the invention for producing a finished component (15) comprising an electronic element (13).

[0027] The method (100) according to the invention comprises the injection (105) of a coating material (12) and the coating (106) of an electronic element (13) to produce (108) a protection of the electronic element (13) and to generate (109) a final geometry of the finished component (15) to be produced.

[0028] Preferably, in a prior, first step, a retaining element for the electronic element (13) is manufactured (101a). Subsequently, the electronic element (13) can be attached to the retaining element (101b). This can be followed by inserting and positioning (101c) the retaining element, including the electronic element (13), in a temperature-controlled tool (10), and fixing (101d) the retaining element.

[0029] Subsequently, a textile reinforcement element (14) can be inserted into the temperature-controlled tool (10) and positioned (103). The temperature-controlled tool (10) is then closed (104). A coating material (12) is injected (105) into the interior of the temperature-controlled tool (10), and the electronic element (13) along with the retaining element is encased (106) by the coating material (12). Preferably, the coating material (12) is then cured (107), thus creating (108) a protective layer for the electronic element (13) and producing (109) the final geometry of the finished component (15). The temperature-controlled tool (10) is opened, and the finished component (15) is ejected (110). The finished component (15) can be a structural component or a basic structure which is subsequently assembled onto another component, advantageously a structural component (111).

[0030] Alternatively, the electronic element (13) can be inserted into a temperature-controlled tool (10) and positioned without a holding element (102a). The electronic element (13) can also be fixed in place (102b). Subsequently, a textile reinforcement element (14) can be inserted into the temperature-controlled tool (10) and positioned (103). After closing (104) the temperature-controlled tool (10), a coating compound (12) is injected (105) and the electronic element (13) is encased (106). After the coating compound (12) has hardened (107), the electronic element (13) is protected (108), and the final geometry of the finished component (15) is created (109). After opening the tool, the finished component (15) is ejected (110). The finished component (15) can be a structural component or a basic structure which is subsequently assembled onto another component, advantageously a structural component (111).

[0031] The Fig. Figures 2a to 2d show a temperature-controlled tool (10) for carrying out the method (100) according to the invention. Fig. 1 after various procedural steps.

[0032] Fig. Figure 2a shows the temperature-controlled tool (10) comprising an upper part (10a) and a lower part (10b) in the open state after the insertion and positioning (102a) of an electronic element (13) and the insertion and positioning (103) of a textile reinforcement element (14). The temperature-controlled tool (10) is then closed (104).

[0033] Fig. Figure 2b shows the closed, temperature-controlled tool (10) after the injection (105) of a coating material (12) by means of a metering unit (11). The coating material (12) completely encloses the electronic element (13) and impregnates the reinforcing element (14).

[0034] Fig. Figure 2c shows the tempered tool (10) after curing (107) of the coating material (12). The tempered tool (10) is still in the closed state.

[0035] In Fig. Figure 2d shows the opened, temperature-controlled tool (10) after the coating material (12) has cured. The finished component (15) can now be removed. Reference symbol list 100 methods for manufacturing a finished component comprising an electronic element 101a Production of a retaining element 101b Attaching the electronic element to the retaining element 101c Inserting and positioning the retaining element, including the electronic element, in a temperature-controlled tool 101d Securing the retaining element 102a Inserting and positioning the electronic component in a temperature-controlled tool 102b Fixing the electronic component 103 Inserting and positioning a textile reinforcement element in the temperature-controlled tool 104 Closing the tempered tool 105 Injection of a coating mass 106 Enclosure of the electronic element 107 Curing of the coating compound 108 Manufacturing a protective device for the electronic component 109 Generating a final geometry of the finished component 110 Opening the tool and ejecting the finished component 111 Assembly on another component 10 tempered tools 10a upper part 10b lower part 11 dosing units 12 Enveloping compound 13 Electronic element 14 textile reinforcement element 15 finished components

Claims

[1] Method (100) for manufacturing a finished component (15) comprising an electronic element (13), wherein the method (100) comprises the injection (105) of a coating material (12) and the coating (106) of the electronic element (13) to produce (108) a protection of the electronic element (13) and to simultaneously generate (109) a final geometry of the finished component (15), characterized by , that for the injection (105) and the coating (106) no injection molding process is used, wherein the process is a low-pressure plastic casting process, wherein the process (100) uses a processing temperature of at most 200°C and an internal tool pressure of at most 70 bar, the process does not include any further step to produce a desired final geometry of the component, wherein the coating mass (12) is a reactive thermoplastic mass, namely a low viscosity matrix system, wherein the coating mass (12) comprises caprolactam, wherein the method (100) comprises inserting and positioning (102a) the electronic element (13) into a temperature-controlled tool (10), wherein the method comprises inserting and positioning (103) a textile reinforcement element (14), namely an endless fiber reinforced semi-finished product, into the tempered tool (10). [2] Method (100) according to claim 1, characterized by , that the encapsulation mass (12) has elastic-soft properties. [3] Method (100) according to any one of the preceding claims, characterized by , that the process (100) includes the curing of the coating mass (12).

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