Method for manufacturing a vehicle part, vehicle part and vehicle

Abstract

A method for manufacturing a vehicle part (10) is proposed. The method comprises the following steps: • (S1) Applying a film (14), in particular an adhesion promoter film, to a carrier part (12), • (S2) Printing at least one geometric structure (18) onto the film (14) using a 3D printing process, wherein during the printing of the geometric structure (18) the film (14) melts at least partially and welds to the geometric structure (18).

Description

[0001] The invention relates generally to the field of vehicle parts. In particular, the invention relates to a method for manufacturing a vehicle part, a vehicle part, and a vehicle with such a vehicle part.

[0002] In component manufacturing, the forming capabilities of semi-finished products are often limited, making it necessary to apply additional plastic elements, such as fasteners, protective elements, or decorative elements, to a substrate. The separate production of such elements and their subsequent application to a substrate can be very costly. In current technology, this is typically achieved by welding, bonding, or overmolding during the injection molding process. However, this entire process chain for manufacturing and applying the additional elements is very complex and requires significant investment in production infrastructure, such as equipment and tooling. Additional handling and pretreatment steps further increase manufacturing costs, especially for small production runs.

[0003] The object of the present invention is to at least partially solve the aforementioned problems. In particular, the object of the present invention is to provide a method for manufacturing a vehicle part in which additional elements can be 3D-printed directly onto a substrate. Furthermore, the invention aims to provide a flexible and cost-effective method for manufacturing a vehicle part.

[0004] The invention is defined in the independent claims. Advantageous embodiments of the invention are described in the dependent claims and the following description.

[0005] A first aspect of the present disclosure relates to a method for manufacturing a vehicle part. The method comprises the following steps: • Applying a film, in particular an adhesion promoter film, to a substrate, • Printing at least one geometric structure onto the film using a 3D printing process. During the printing process, the film melts at least partially and fuses with the geometric structure.

[0006] A method is proposed which, in a first step, involves applying a film to a substrate. Specifically, a film can be applied to a surface of the substrate to form a semi-finished product. The application of the film can be part of the overall manufacturing process of the semi-finished product. For example, the film can be applied to a surface of the substrate while the semi-finished product is being manufactured. The tool used to manufacture the semi-finished product can also be used to apply the film to the substrate. The film preferably comprises a first material. The substrate preferably comprises a second material that differs from the first material. The film can be liquid or viscous during application and can, in particular by hardening, form a layer on a surface of the substrate.The film can, in particular, completely cover one surface of the substrate. Alternatively, the film can be applied only to a first section of the substrate. This first section is preferably a section onto which a geometric structure is to be printed.

[0007] To complete or manufacture the semi-finished product, the film and the substrate can be formed or deformed together. For example, the film can be pre-positioned on the substrate and applied to it using a compression molding process. Such a compression molding process can serve to deform both the film and the substrate. The film can therefore be applied to, or joined with, the substrate essentially simultaneously with its deformation. The deformed substrate together with the film can be referred to as a semi-finished product. This semi-finished product can therefore have a three-dimensional geometry.

[0008] After applying the film, which can form a thin layer, in particular a surface layer of the substrate, at least one geometric structure is printed onto the film using a 3D printing process. This means that a geometric structure can be printed onto the semi-finished product, which already has a three-dimensional geometry. In particular, a three-dimensional structure is printed directly onto the film, for which an additive manufacturing process can be used. In other words, the geometric structure can be printed directly onto the semi-finished product. In the context of this disclosure, 3D printing processes include, in particular, additive manufacturing processes. The geometric structure can serve to functionalize and / or personalize the semi-finished product, or the substrate including the film. The geometric structure can be referred to as an additional element.The semi-finished product can also be referred to as the substrate, with the semi-finished product, comprising at least one geometric structure, forming the vehicle part. By printing the geometric structure, the film, and in particular the contact surface between the film and the geometric structure, can at least partially melt and fuse with the geometric structure. A material-bonded connection between the film and the geometric structure can be created using the 3D printing process. This allows the geometric structure to be joined to the substrate, at least indirectly. The semi-finished product can be connected or joined by melting the film to the geometric structure. Thus, additional process steps, such as welding and / or bonding the geometric structure to the film, can be completely eliminated. Preferably, after printing the at least one geometric structure onto the film, the vehicle part, i.e.,The semi-finished product with the geometric structure, not further deformed.

[0009] Because the film can be applied to the carrier part during the production of the semi-finished product, additional and complex process steps can be avoided.

[0010] The geometric structure can be printed directly onto the film of the semi-finished product. This allows for cost- and time-efficient modification of the geometry of a carrier part or semi-finished product for the production of a vehicle component. The proposed method simplifies the process chain for manufacturing the vehicle component. In particular, the application of additional elements to a carrier part can be simplified, as pretreatment steps of the carrier part and / or the complex joining of the geometric structure to the film can be eliminated. This can lead to lower manufacturing costs.

[0011] The vehicle part in question can be a component designed to be integrated into a plastic component housing. It can be an interior vehicle component, and in particular, a part of a vehicle's instrument panel.

[0012] According to one embodiment, the film comprises polyamide, polyester, and / or polypropylene. The film can be an adhesion promoter film. In particular, the film can comprise a first material selected from the group consisting of polyamide, polyester, and polypropylene. The choice of the first material of the film can depend on the material used for printing the geometric structure, i.e., the printing material. Preferably, the first material of the film comprises the printing material. This allows the film to melt more readily during the printing of the geometric structure, since the film can have a melting temperature range that at least partially overlaps with the melting temperature range of the printing material. The term "melting temperature range" can refer to a temperature range that includes the corresponding melting point but extends to just below the corresponding boiling point.The printing material can also be a material selected from the group comprising polyamide, polyester and polypropylene.

[0013] According to one embodiment, the film is painted on at least one side. To improve the adhesion of the film to the substrate, the film can be painted before being applied to the substrate. Alternatively or additionally, the film can be painted, at least in certain areas, after being applied to the substrate. This can improve the bonding of the film to the geometric structure.

[0014] According to one embodiment, the support component comprises natural fibers and / or plastic. The support component can consist predominantly of natural fibers, such as wood fibers. In particular, the support component can consist predominantly of compressed wood fibers. The support component can, for example, have a layered structure. The support component can have a wood fiber layer, which, for example, forms the core of the support component. The support component can have further layers comprising additional natural fibers. The support component can also include a binder and / or a plastic. It is conceivable that the natural fibers are mixed with a binder or a plastic. The support component can further be manufactured using a press. In particular, the support component can be pressed under high pressure.

[0015] According to one embodiment, the film is applied to the carrier part, particularly to a surface of the carrier part, by gluing, welding, and / or pressing. Specifically, the film is applied to a surface of the carrier part during the manufacturing process of the semi-finished product. If the semi-finished product is manufactured by gluing natural fibers, the film can be glued to the surface of the carrier part simultaneously. Alternatively, if the carrier part is manufactured by pressing, the film can be applied to the surface of the carrier part in the same pressing process. The press used to manufacture the carrier part can be designed to hold a film and press it onto a surface of the carrier part. Such a press can be a forming press and can be used to deform the carrier part together with the film. In this way, the film and the carrier part can be joined to form a semi-finished product in a time- and cost-efficient manner.

[0016] According to one embodiment, the geometric structure forms a functionalization element. Examples of such a functionalization element include brackets, fasteners, protective elements, screw connections, guides, and housings. Such a functionalization element can be designed to integrate the vehicle component into an existing installation space. In this way, a semi-finished product, i.e., a carrier part including the film, which can be easily mass-produced, can be individually functionalized for a variety of different applications.

[0017] According to one embodiment, the substrate and / or the film are measured using a measuring unit before the geometric structure is printed. Based on the measurement of the substrate and film, the geometric structure is printed. A 3D printing system, which includes a measuring unit, can be used to print the geometric structure. Such a measuring unit can measure and, in particular, analyze the substrate and / or film, i.e., the semi-finished product. For example, the measuring unit can measure and / or record the geometric dimensions of the semi-finished product. Additionally or alternatively, the measuring unit can record where the film is positioned on the surface of the substrate. The dimensions of the film can also be recorded. Based on the measurement, i.e., on the recorded dimensions of the substrate and / or film, the geometric structure can be printed.The 3D printing system can therefore be controlled in such a way that the measured dimensions of the substrate and / or film are taken into account when printing the geometric structure. The 3D printing system, in particular its control unit, can compensate for any dimensional deviations of the substrate and / or film during the printing process. For example, a print head of the 3D printing system can guide a tactile sensor onto the surface of the film to check the position of the substrate before printing the geometric structure. This prevents the 3D printing system from printing a geometric structure in the wrong location.

[0018] A second aspect of the present disclosure relates to a vehicle part which is manufactured according to a process as described above and / or below.

[0019] All advantages, disclosures and / or statements described above and / or below in relation to the process for manufacturing the vehicle part apply equally to the vehicle part, and vice versa.

[0020] A third aspect of the present disclosure relates to a vehicle which has at least one vehicle part as described above and / or below.

[0021] All benefits, revelations and / or explanations described above and / or below in relation to one aspect of the present revelation apply equally to all other aspects of the present revelation.

[0022] Exemplary embodiments of the invention are described below with reference to the figures. The figures show: Fig. 1 a vehicle part according to an exemplary embodiment and Fig. 2 a flowchart of a process according to an exemplary embodiment.

[0023] Similar, similar-looking, identical, or equivalent elements are marked with similar or identical reference symbols in the figures. The figures are merely schematic and not to scale.

[0024] Fig. Figure 1 shows a vehicle part 10 according to an exemplary embodiment. The vehicle part 10 of the Fig. 1 is produced according to a procedure as described above and / or below (see below). Fig. 2) The vehicle part 10 has a support part 12, which preferably comprises wood fibers. The support part 12 can, for example, comprise a core of wood fibers and layers arranged around the core that comprise other natural fibers. The support part 12 is, in particular, coated with at least one film 14. The film 14 is applied to a surface of the support part 12. It covers at least part of a surface of the support part 12. In the exemplary embodiment of the Fig. In Figure 1, the vehicle part 10 has two films 14. For the sake of simplicity, only a single film 14 will be referred to in the following. However, this does not preclude the vehicle part 10 from having multiple films 14. The film 14 preferably comprises polyamide, polyester, and / or polypropylene. The vehicle part 10 also has at least one geometric structure 18. The geometric structure 18 is preferably arranged on the surface 13 of the film 14. The geometric structure 18 can, in particular, be bonded to the film 14. The bond can be created by printing the geometric structure 18 onto the surface 13 of the film 14 using a 3D printing process. Furthermore, the bond can be created by a suitable material selection for the film 14 and / or the geometric structure 18, or the printing material.The geometric structure 18 can comprise polyamide, polyester and / or polypropylene. In particular, the geometric structure 18 can comprise or be made of a plastic.

[0025] The geometric structure 18 can be a functionalization element. The geometric structure 18 can be configured to functionalize the carrier part 12, or the vehicle part 10, particularly for the intended use of the vehicle part 10. The geometric structure 18 is preferably a three-dimensional element. It can be, for example, a holder, a housing, or a screw boss. Although in Fig. 1. If the vehicle part 10 has only one geometric structure 18, it is not excluded that the vehicle part 10 has several geometric structures 18, for example on different surfaces of the vehicle part 10, or on surfaces 13 of different films 14.

[0026] It should be noted that although the carrier part 12 of the Fig. The support element 12 is plate-shaped and flat, and can have simple geometries and / or cross-sections. The support element 12 can, for example, have curves and / or extend in all three spatial directions. However, for the series production of a vehicle part 10, it may be crucial that the support element 12 does not have complex surface structures or protrusions. The support element 12 is preferably quick and easy to manufacture using a press tool.

[0027] Fig.Figure 2 shows a flowchart of a process for manufacturing a vehicle part 10 according to an exemplary embodiment. In a first process step S1, a film 14 is applied to a carrier part 12. The first process step S1 can correspond to the production of a semi-finished product 16 consisting of the carrier part 12 and at least one film 14. This means that, in essence, a semi-finished product 16 can be completed in the first process step S1, wherein the semi-finished product 16 comprises the carrier part 12 and at least one film 14. Preferably, the film 14 is applied during the completion of the semi-finished product 16. The film 14 can be applied to the carrier part 12, in particular to a surface of the carrier part 12, by gluing, welding, and / or pressing. The film 14 is preferably applied to the carrier part 12 by the same method used to manufacture the semi-finished product 16 itself.This means that if the semi-finished product 16 is manufactured by compression molding, the film 14 is preferably also applied to the carrier part 12 by compression molding. During the manufacture of the semi-finished product 16, i.e., during the application of the film 14 to the carrier part 12, the carrier part 12 can be deformed together with the film 14.

[0028] In a second process step S2, which is preferably carried out after the first process step S1, a geometric structure 18 is printed onto a surface 13 of the film 14 using a 3D printing process. The 3D printing process can be a laser sintering process (LSP). An LSP process is an additive manufacturing process. High manufacturing accuracy and surface quality can be achieved through an LSP process. Furthermore, the use of an LSP process enables the printing of complex geometries. During the printing of the at least one geometric structure 18, the film 14 melts at least partially and fuses with the geometric structure 18. This allows the film 14 and the geometric structure 18 to be joined.This means that a connection between the two chemically foreign materials, the semi-finished product 16 and the geometric structure 18, can be created by melting and welding the printing material of the geometric structure 18 with the film 14, in particular the adhesion promoter film.

[0029] Using a method as described above, for example, a wooden support structure, i.e., a semi-finished product 16, can be integrated into an existing installation space, while existing attachments designed for a plastic support structure can continue to be used without any changes to their geometry. For this purpose, the method can involve printing a geometric structure 18, which cannot be manufactured in wood or only with great difficulty, directly onto a prefabricated wooden part, or a semi-finished product 16, using a 3D printing process. The geometric structure 18 is preferably printed onto an already deformed semi-finished product. After printing the geometric structure 18, the vehicle part 10 is preferably finished and does not require any further deformation.

[0030] It should be further noted that the terms "comprising" and "comprising" do not exclude other elements, and the indefinite articles "a" or "an" do not exclude a plurality. It should also be noted that features and steps described with reference to one of the above embodiments may also be used in combination with other features and steps of other embodiments described above. Reference numerals in the claims are not to be considered limitations. Reference symbol list 10 vehicle part 12 Carrier part 13 Surface of the film Slide 14 16 semi-finished products 18 geometric structure S1 first process step S2 second procedure step

Claims

[1] Method for manufacturing a vehicle part (10) comprising the following steps: • (S1) Applying a film (14), in particular an adhesion promoter film, to a carrier part (12), • (S2) Printing at least one geometric structure (18) onto the film (14) using a 3D printing process, wherein during the printing of the geometric structure (18) the film (14) melts at least partially and welds to the geometric structure (18). [2] Method according to claim 1, wherein the film (14) comprises polyamide, polyester and / or polypropylene. [3] Method according to one of the preceding claims, wherein the film (14) is painted at least on one side. [4] Method according to one of the preceding claims, wherein the support part (14) comprises natural fibers and / or a plastic. [5] Method according to one of the preceding claims, wherein the film (14) is applied to the carrier part (12), in particular to a surface of the carrier part (12), by gluing, welding and / or pressing. [6] Method according to any of the preceding claims, wherein the geometric structure (18) forms a functionalization element. [7] Method according to one of the preceding claims, wherein the carrier part (12) and / or the film (14) is measured by means of a measuring unit before the geometric structure (18) is printed and wherein the geometric structure (18) is printed on the carrier part (12) together with the film (14). [8] Vehicle part (10) which is manufactured according to a method according to one of the preceding claims. [9] Vehicle comprising at least one vehicle part according to claim 8.

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