Method for injection joining an aluminum profile

Abstract

Method for injection joining an aluminium profile, comprising: a product preparation process (S110) of manufacturing a plurality of aluminium profiles (10) which are to be joined according to a product design, a mold preparation operation (S120) of manufacturing a mold (20) designed according to the aluminium profiles (10) prepared by the product preparation operation (S110), a setting process (S130) of setting the majority of aluminium profiles (10) to be joined in the forming tool (20) in a state in which they are in contact with each other, and an injection filling process (S140) of constructing the aluminium profiles (10) which are to be joined in an integrated form, by filling contact sections of the aluminium profiles (10) with an injection-molded material (50) through the mold tool (20), wherein the injection filling process (140) has a side passage opening forming process (S141) of guiding the injection-molded material (50), which is to be joined with the aluminium profiles (10) in an integrated mold, by mechanically creating a passage opening (12) in a side face of each of the aluminium profiles (10), and a bolt insertion process (S142) of connecting the injection-molded material (50) with the aluminium profiles (10) in the integrated mold by inserting a bolt (30) into the through-hole (12) formed by the side through-hole forming process (S141).

Description

[0001] The invention relates to a method for injection joining an aluminum profile, and in particular a method for injection joining an aluminum profile for an electric vehicle battery housing.

[0002] The invention relates to a method for joining a plurality of aluminium profiles forming an electric vehicle battery housing and is intended to solve the problems of a prior art method for joining by welding.

[0003] In the case of the state-of-the-art welding process, a problem arises because the aluminum profile is deformed after welding. This is particularly problematic because aluminum profiles are susceptible to deformation from heat of 500 to 600 degrees Celsius; the heat generated during welding causes the aluminum profile to undergo thermal deformation.

[0004] For this reason, producing a desired structure by welding multiple aluminum profiles requires multiple deformation-prevention elements and multiple additional post-welding processes to prevent weld deformation. Consequently, the state-of-the-art welding method suffers from the difficulty of precisely meeting tolerances such as flatness and opening positions. Furthermore, the weld interacts with a fastening element, necessitating the removal of weld spatter by grinding. This creates additional problems, makes achieving flatness difficult, and carries a very high risk of leakage.

[0005] Furthermore, in the case of the welding process according to the state of the art, it is very difficult to rework after a welding defect has been detected, and therefore there is a problem that a product with the welding defect has to be thrown away.

[0006] Therefore, there is a need for a technology suitable to solve the problems caused by the aforementioned state of the art, to simplify the process of joining according to the state of the art, to prevent deformation of products and to essentially eliminate the risk of leakage.

[0007] For example, a composite aluminum profile is known from DE 10 2010 036 641 A1, wherein the composite aluminum profile is produced by: producing a plurality of aluminum profiles which are to be joined according to a product design, producing a forming tool which is designed according to the aluminum profiles, placing the plurality of aluminum profiles to be joined into the forming tool in a state in which they are in contact with each other, and constructing the aluminum profile by filling contact sections of the aluminum profiles with an injection-molded material through the forming tool.

[0008] Other examples of the state of the art include: KR 10 1 277 453 B1, which describes a method for producing aluminium welded structures. DE 10 2009 052 110 A1, wherein a motor vehicle front end is described, consisting of at least one base body and at least one first thermoplastic plastic part and a second thermoplastic plastic part. DE 24 44 267 A1, wherein a method for manufacturing an object made of plastic is described, in which at least one surface formed in an injection mold is covered with metal. DE 22 35 791 A, wherein a method for manufacturing tennis rackets is described, wherein plastic strips are attached to a tension frame made of light metal and are deformed under the influence of temperature. DE 40 40 048 A1 concerning a core profile for reinforcing plastic products. DE 10 2017 010 863 A1, wherein a method for manufacturing a battery tray is described, comprising the steps: arranging several metallic hollow profile elements forming a tray base in the cavity of an open plastic mold, and closing the plastic mold and producing a plastic frame.

[0009] The invention aims to create a method for injection joining an aluminum profile that is suitable for easily joining aluminum profiles with different cross-sectional structures, maintaining a stable joint state and therefore eliminating a plurality of connecting or bonding elements in order to significantly reduce the costs required for manufacturing and construction and also to significantly shorten the design time for the production of an electric vehicle battery housing.

[0010] That is to say, according to the invention, a method for injection bonding an aluminum profile with the features of claim 1 is provided. Further embodiments are described in the dependent claims.

[0011] Thus, a method for injection joining an aluminum profile is provided, comprising a product preparation process of manufacturing a plurality of aluminum profiles which are to be joined (to each other) according to a product design, a mold preparation process (e.g., an injection mold preparation process) of manufacturing a mold (e.g., an injection mold) which is designed according to the aluminum profiles that are prepared by the product preparation process, a placement process (e.g., a receiving process) of placing (e.g., receiving) the plurality of aluminum profiles to be joined in the mold (e.g., in the injection mold) in a state in which they are in contact (e.g., in contact contact) with each other, and an injection filling process of constructing (e.g.,of the assembly) of the aluminium profiles which are to be joined (to each other) in an integrated form, by filling contact sections of the aluminium profiles with an injection-molded material (e.g. an injection molding material) through the mold tool (e.g. through the injection mold).

[0012] According to the aspect of the invention, the mold preparation process can include a mold gate forming process (e.g., a mold sprue forming process, e.g., a mold outlet forming process, e.g., an injection mold outlet forming process) of forming a mold gate (e.g., a mold sprue, e.g., a mold outlet, e.g., an injection mold outlet) with a structure that makes it possible to discharge the injection-molded material via the mold and guide it into an aluminum profile connection section according to a forming position of a filling opening of each of the aluminum profiles.

[0013] Furthermore, the injection filling process includes a side-through opening forming process for guiding the injection-molded material, which is to be connected to the aluminum profiles in an integrated form by creating (e.g. via machining) a through-opening in a side surface of each of the aluminum profiles.

[0014] Furthermore, the injection filling process includes a bolt insertion process (e.g. a pin insertion process) for connecting the injection-molded material with the aluminum profiles in the integrated mold by inserting a bolt (e.g. a pin) into the through-hole formed by the side through-hole forming process.

[0015] According to the aspect of the invention, the injection filling process can include a block assembly process of mounting a block in the aluminium profiles to form a space with a predetermined volume adjacent to a connecting section in each of the aluminium profiles.

[0016] The invention will be explained in more detail with reference to the drawings. The drawings show: Fig. 1. An illustration depicting a process of joining an aluminium profile according to the state of the art; Fig. 2 an illustration depicting a state of aluminium profiles joined by a welding process according to the state of the art; Fig. 3 a flowchart illustrating a method for joining an aluminium profile according to an embodiment of the invention; Fig. 4 a flowchart illustrating a method for joining an aluminium profile according to another embodiment of the invention; Fig. 5 a perspective view that presents an example in which a filling opening is formed in a state in which two aluminium profiles to be joined are in contact with each other; Fig. 6 A schematic top view representing a state in which a plurality of aluminium profiles, in contact with each other, are seated in a forming tool, as in Fig. 5 is shown; Fig. 7 A schematic top view representing a state in which the inner surfaces of the aluminum profiles are coated with an injection-molded material from the one in Fig. The 6 shown mold tool is filled; Fig. 8 a schematic top view showing a state in which the inner surfaces of the aluminium profiles are filled with the injection-molded material from a mold in a state in which blocks are inserted into the aluminium profiles; and Fig. 9 a perspective view showing an example of inserting a bolt after forming a through-hole in an aluminum profile.

[0017] Preferred embodiments of the invention are described in detail below with reference to the drawings.

[0018] Fig. Figure 3 is a flowchart illustrating a method for joining an aluminum profile according to an embodiment of the invention.

[0019] With reference to Fig. 3. Since a method for joining an aluminum profile (S100) according to the present embodiment comprises a product preparation operation (S110), a mold preparation operation (S120), a setting operation (S130) and an injection filling operation (S140), each of which performs a specific process, the method for injection joining an aluminum profile can be provided which is suitable for easily joining aluminum profiles with different cross-sectional structures, maintaining a stable joining state and therefore omitting a plurality of joining or bonding elements in order to significantly reduce the costs required for manufacturing and construction and also to significantly shorten the design time (e.g. assembly time) for the manufacture of an electric vehicle battery housing.

[0020] Each step that constitutes the method for injection joining an aluminium profile (S100) according to the present embodiment is described in detail below with reference to the drawings.

[0021] Fig. Figure 4 is a flowchart illustrating a method for joining an aluminum profile according to another embodiment of the invention, and Fig. Figure 5 is a perspective view that shows an example in which a filling opening is formed in a state in which two aluminium profiles to be joined are in contact with each other. Fig. Figure 6 is a schematic top view depicting a state in which a plurality of aluminium profiles, in contact with each other, are seated in a mold (e.g., in an injection mold), as shown in Fig. 5 is shown, Fig. Figure 7 is a schematic top view depicting a state in which the inner surfaces of the aluminum profiles are coated with an injection-molded material (e.g., an injection molding material) from the one shown in Fig. The 6 shown mold tool is filled, and Fig. Figure 8 is a schematic top view depicting a state in which the inner surfaces of the aluminum profiles are filled with the injection-molded material, with blocks inserted into the aluminum profiles. Furthermore, Fig. 9 a perspective view showing an example of inserting a bolt after forming a through-hole in an aluminum profile.

[0022] The product preparation process (S110) according to the present embodiment involves a process of manufacturing a plurality of aluminium profiles which are to be joined according to a product design.

[0023] The tool preparation process (e.g. the injection mold preparation process) (S120) according to the present embodiment carries out a process of manufacturing a tool (e.g. an injection mold) that is designed according to the aluminium profiles prepared by the product preparation process (S110).

[0024] Specifically, the mold preparation operation (S120) can include a mold gate forming operation (e.g., a mold exit forming operation, e.g., an injection mold exit forming operation) (S121), a side passage opening forming operation (S141), a bolt insertion operation (S142), and a block assembly operation (S143), each of which performs a specific process. The mold gate forming operation (S121) of the mold preparation operation (S120) performs a process of forming a mold gate (e.g., a mold exit, e.g., an injection mold exit) with a structure that allows the injection-molded material 50 to be discharged through the mold 20 and guided into an aluminum profile connection section according to a forming position of a filling opening 11 of each of the aluminum profiles. As in the Fig. 6 and Fig. As shown in Figure 9, the side-through-opening forming process (S141) involves guiding the injection-molded material 50, which is to be joined with the aluminum profiles 10 in an integrated mold, by mechanically creating (e.g., by machining) a through-opening 12 in a side face of each of the aluminum profiles 10. As shown in Fig. As shown in Figure 9, the bolt insertion process (S142) involves joining the injection-molded material 50 to the aluminum profiles 10 in the integrated mold by inserting a bolt 30 into the through-hole 12 formed by the side-through-hole forming process (S141). Fig. As shown in Figure 8, the block assembly process (S143) involves a process of assembling a block 40 into the aluminum profiles 10 to form a space of a predetermined volume adjacent to a connecting section in each of the aluminum profiles 10.

[0025] The setting process (S130) according to the present embodiment carries out a process of manufacturing a forming tool 20 which is designed according to the aluminium profiles which are prepared by the product preparation process (S110).

[0026] The injection filling process (S140) according to the present embodiment carries out a process of constructing (e.g. assembling) the aluminium profiles which are to be joined in an integrated form by filling contact sections of the aluminium profiles with an injection-molded material (e.g. an injection molding material) 50 through the mold tool 20.

[0027] As described above, according to the invention, by including the product preparation process (S110), the mold preparation process (S120), the setting process (S130) and the injection filling process (S140), each of which carries out a specific process, a method for injection joining an aluminum profile (S100) can be provided which is suitable for easily joining aluminum profiles with different cross-sectional structures, maintaining a stable joint state and therefore eliminating a plurality of connecting or bonding elements in order to significantly reduce the costs required for manufacturing and construction and also to significantly shorten the design time for the manufacture of an electric vehicle battery housing.

[0028] As described above, according to the invention, by including a product preparation process, a mold preparation process, a setting process and an injection filling process, each of which carries out a specific process, a method for injection joining an aluminum profile can be provided which is suitable for easily joining aluminum profiles with different cross-sectional structures, maintaining a stable joint state and therefore omitting a plurality of connecting or bonding elements in order to significantly reduce the costs required for manufacturing and construction and also to significantly shorten the design time for the manufacture of an electric vehicle battery housing. Reference symbol list 10 aluminum profiles 11 Filling opening 12. Passage opening 20 forming tools 30 bolts 40 blocks 50 injection-molded material S110 Product Preparation Process S120 Mold preparation process S121 Mold cutting process S130 setting process S140 injection filling process S141 Side-through opening forming process S142 Bolt insertion procedure S143 Block assembly process

Claims

[1] Method for injection joining an aluminium profile, comprising: a product preparation process (S110) of manufacturing a plurality of aluminium profiles (10) which are to be joined according to a product design, a mold preparation operation (S120) of manufacturing a mold (20) designed according to the aluminium profiles (10) prepared by the product preparation operation (S110), a setting process (S130) of setting the majority of aluminium profiles (10) to be joined in the forming tool (20) in a state in which they are in contact with each other, and an injection filling process (S140) of constructing the aluminium profiles (10) which are to be joined in an integrated form, by filling contact sections of the aluminium profiles (10) with an injection-molded material (50) through the mold tool (20), wherein the injection filling process (140) has a side passage opening forming process (S141) of guiding the injection-molded material (50), which is to be joined with the aluminium profiles (10) in an integrated mold, by mechanically creating a passage opening (12) in a side face of each of the aluminium profiles (10), and a bolt insertion process (S142) of connecting the injection-molded material (50) with the aluminium profiles (10) in the integrated mold by inserting a bolt (30) into the through-hole (12) formed by the side through-hole forming process (S141). [2] Method according to claim 1, wherein the mold preparation process (S120) comprises a mold gate forming process (S121) of forming a mold gate with a structure that enables the injection-molded material (50) to be discharged via the mold (20) and guided into an aluminum profile connection section according to a forming position of a filling opening (11) of each of the aluminum profiles (10). [3] Method according to claim 1 or 2, wherein the injection filling process (S140) comprises a block assembly process (S143) of assembling a block (40) in the aluminium profiles (10) to form a space with a predetermined volume adjacent to a connecting section in each of the aluminium profiles (10).

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