Method and device for producing hybrid structures not requiring finishing
Patent Information
- Application Number
- EP2023836345
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-12-12
- Filing Date
- 2023-12-12
- Publication Date
- 2025-10-22
Smart Images

Figure 1.1
Abstract
Description
[0001] Method and device for the rework-free production of hybrid structures
[0002] TECHNICAL FIELD
[0003] The present disclosure relates to an apparatus for manufacturing a hybrid structure and to a corresponding manufacturing method.
[0004] TECHNICAL BACKGROUND
[0005] Cold gas spraying is a modern process in the field of thermal spraying. Compared to conventional processes, cold gas spraying offers particular advantages because the spray material is neither partially melted nor completely melted during the process. This minimizes the thermal influence on the layer and substrate. In cold gas spraying, a carrier gas (e.g., nitrogen) is heated under pressure, which enables a higher gas velocity. Particles of the material to be applied are then fed in and accelerated by the gas, achieving high kinetic energy of the particles. The accelerated particles are guided through a cooled convergent-divergent nozzle (DeLaval nozzle). After the particles hit the surface, they deform plastically and bond to the substrate to form a (highly) strong composite. According to the current state of science, the particles do not melt.
[0006] Additive processes often require various pre- and post-processing steps, such as prior grinding of a surface onto which the material is to be sprayed, or the subsequent sealing or irradiation of the sprayed material. In conventional additive processes (which do not use cold spraying), combining the additive process with such pre- and post-processing is not possible or only possible to a limited extent due to the thermal input of the additive process (e.g., through conventional spraying processes in which the spray material is heated / melted, or through build-up welding). The emissions (e.g., laser radiation) of previous processes therefore do not allow a combination in the same end effector, or only to a very limited extent. i DESCRIPTION
[0007] Accordingly, it is an object of the invention to provide a modular device and a method with shortened process time, integrated referencing and improved additive construction.
[0008] This object is achieved by the subject matter of the independent claims. Further embodiments emerge from the dependent claims and the following description.
[0009] According to a first aspect, a device for manufacturing hybrid structures is provided. The device comprises a cold gas spray head, a processing module, and a controller. The cold gas spray head and the processing module are arranged in a common unit. The controller is configured to control the operation of the cold gas spray head and the processing module such that a first work step is performed by the cold gas spray head and a second work step is performed by the processing module, wherein the first work step and the second work step are initiated sequentially or simultaneously.
[0010] Hybrid structures can be understood as structures composed of different composite materials, e.g., in the form of different material layers. For example, these could be circuit boards with applied conductive tracks, a battery assembly with a battery layer with a thin metal layer and an insulator on top, or any other similarly constructed structure. The different layers do not necessarily have to be congruent. However, the above list is only exemplary.
[0011] Such hybrid structures can be manufactured, for example, by spraying a layer (or a partial layer) onto a base material / carrier material. The final product is manufactured using an additive process. To minimize the thermal impact of the spraying process on the carrier material, cold gas spraying processes are particularly advantageous because they prevent the sprayed material from melting or melting. However, in various applications, pre-processing of the carrier material (or of a previously applied layer before a further layer is applied) or post-processing of the applied layers is necessary. For example, it may be necessary to prepare a surface by milling, grinding, honing, or other processes before a material layer is sprayed on, for example to improve the surface quality or to enable adaptation to a final dimension.Furthermore, it may be necessary to rework an applied layer of material, for example by applying a sealant.
[0012] The implementation of such pre- and / or post-processing steps with the spraying step is not possible or only very limitedly possible together in a common unit in existing additive processes, such as injection molding processes in which the spray material is heated, due to the thermal input into the carrier material.
[0013] The present proposal is to combine cold gas spraying processes with the execution of various and arbitrary pre- and / or post-processing steps due to the absence or at least significantly reduced thermal input. This allows different work steps to be carried out sequentially or, in some cases, simultaneously by a single device by arranging corresponding processing modules in a common unit. This significantly reduces process time, as the workpiece does not have to be desynchronized and transferred to another device to carry out the pre- and / or post-processing processes. Furthermore, this provides automatic, integrated referencing, as the cold gas spray head and the corresponding processing module(s) are arranged in a fixed spatial relationship to one another in the common unit.This enables precise, sequential execution of various work steps in one go.
[0014] The fact that the first work step and the second work step are initiated consecutively or simultaneously means that these two work steps are started at different (consecutive) times or both at (at least essentially) the same time. For example, the first work step can be started first and then, after a certain period of time, the second work step can be started. However, the first work step and the second work step can also be initiated at the same time. Furthermore, the second work step can also be started, for example, while the first work step is still being executed or after the first work step has been completed.For example, the cold gas spray head and the processing module are arranged in such a way that the first work step and the second work step can be carried out at least partially at the same time, but at different positions of the manufactured hybrid structure.
[0015] The common unit is defined by a common housing in which the cold gas spray head and the processing module are arranged in close spatial proximity to one another, so that the cold gas spray head and the processing module follow a common path / movement path together by moving or guiding the common unit.
[0016] The cold gas spray head comprises a heater in a housing between a gas supply and a cooled nozzle (e.g., a DeLaval nozzle). A highly compressed gas (e.g., nitrogen) entering through the gas supply is heated by the heater and thereby accelerated toward the nozzle. A material powder can be introduced into the gas stream and is accelerated by the highly compressed gas. When the accelerated particles of the material powder exit the nozzle and impact a surface, the particles undergo plastic deformation and form the corresponding material layer on the substrate.
[0017] The processing module can be any suitable module that performs a corresponding processing step in the manufacture of the hybrid structure, as described below. If the processing module is to perform a pre-processing step prior to cold spraying, the processing module is arranged upstream of the cold spraying head with respect to the movement path of the common unit, so that the movement module first passes over the substrate material, and the corresponding processing step on the substrate material (or on a previously applied layer on the substrate material) is thus performed before cold spraying.If the processing module is to perform a post-processing step after spraying with the cold gas spray head, the processing module is arranged behind the cold gas spray head with respect to the movement path of the common unit, so that the movement module sweeps over the carrier material after the cold gas spray head and the corresponding work step is carried out after the cold gas spraying.
[0018] Furthermore, it should be noted that, although only one processing module is described herein, any number of processing modules may be present in the device in the common unit in a corresponding arrangement in order to carry out a plurality of work steps in immediate succession or partially simultaneously.
[0019] The controller is configured to control all aspects of the operation of the cold spray head and the processing module(s). In particular, the controller can also control the movement of the combined unit over the substrate. The controller can be, for example, a commercially available general-purpose computer with a CPU and appropriate memory components, an FPGA, an ASIC, or any other suitable control unit.
[0020] With regard to the first work step and the second work step, it should be recognized that this does not specify a sequence of the work steps. Rather, the sequence of the work steps results from the intended manufacturing process or from the function of the processing module. For example, the second work step can take place before the first work step if the processing module performs pre-processing, and the second work step can take place after the first work step if the processing module performs post-processing. Furthermore, it should be recognized that in addition to the first work step and the second work step, further work steps (e.g. a third work step, a fourth work step, etc.) may be present, particularly if more than one processing module is present, and the work steps can be carried out in any order according to the intended manufacturing process.
[0021] According to one embodiment, the processing module is an application module for performing an application step, or an ablation module for performing an ablation step. It can also be a module for modifying the material properties (e.g., UV exposure or local heat treatment).
[0022] An application processing module can, for example, be a processing module that applies a sealant or other material layer. An ablation processing module is a processing module that removes material from the substrate or a previously applied layer (e.g., by grinding or similar processes).
[0023] The processing module can also be a module that influences / modifies the properties of the material applied with the cold gas spray head, for example, through energy input, such as a laser, which can be useful in the implementation of laser sintering processes, or a heating module or similar. However, this list is merely exemplary, and other processing modules are also conceivable.
[0024] According to a further embodiment, the processing module is one of a sealing module for applying a seal, a laser module, a grinding module, a milling module and a honing module.
[0025] A sealing module or a laser module, for example, can serve as post-processing modules. Grinding, milling, or honing modules can serve as both pre-processing and post-processing modules.
[0026] According to a further embodiment, the processing module is a second cold gas spray head. With such a second cold gas spray head, for example, a second material layer can be applied over the first immediately after the application of a first material.
[0027] A second layer of material can be applied. The material of the second layer of material can be the same as the first layer of material or can be a different material.
[0028] By providing a second cold gas spray head, the first layer of material does not need to be completely applied first; instead, multiple layers can be applied essentially simultaneously. This is made possible in particular by the fact that with cold gas spraying, the applied material does not need to first cure, as is the case with conventional spraying processes. This shortens the process time for manufacturing multi-layer hybrid structures.
[0029] It should be noted that any number of additional cold gas spray heads can be present in the common unit. Likewise, multiple cold gas spray heads can be used together with one or more processing modules, depending on the intended manufacturing process, i.e., the intended manufacturing steps in producing the hybrid structure.
[0030] According to a further embodiment, the device further comprises a suction device which is arranged in the common unit and which is configured to suck out excess working material from at least one working step.
[0031] Such extraction allows excess material to be removed from the manufactured structure before the next work step in order to avoid contamination in subsequent production steps. Multiple extraction systems can also be provided, e.g., on individual, some, or every sub-module of the common unit, e.g., on each cold gas spray head and on each processing module. The corresponding extraction systems can also be designed such that the extracted material is separated from the individual sub-modules for reuse. According to a further embodiment, the processing module is modularly replaceable and comprises an identifier tag for identifying a type of processing module by the controller.
[0032] For example, each processing module (and also each cold gas spray head) can comprise a corresponding interface for the mechanical coupling of further processing modules and / or cold gas spray heads to the processing module and for the electronic coupling of the further processing modules and / or cold gas spray heads to the control system, so that the control system can also control the operation of the coupled processing modules and / or cold gas spray heads. This creates a flexible modular system that can be easily adapted to different requirements / manufacturing processes. A manufacturing process is understood to mean the execution of specific manufacturing steps by specific sub-modules and their chronological sequence. Different processing modules for different functions are, for example, structurally identical (with regard to shape, size, design, mechanical and electrical specifications, etc.) in order to fit into the same slot orthe same interface of the device can be inserted optionally.
[0033] The cold gas spray head and the additional processing module can also be structurally identical, as described above, so that they can swap positions within the fixture. This allows the cold gas spray head to be positioned either in front of or behind the processing module in the direction of movement when the fixture is moved in a specific direction.
[0034] The identifier tag can, for example, be an RFID tag, which can be read by the controller (e.g., by a corresponding reader attached to the common unit) and provides identification of the corresponding processing module and its type. The controller can thus determine which sub-module is attached at which location.
[0035] According to a further embodiment, the controller is configured to perform a manufacturing process depending on the type of processing module. When a specific configuration of submodules is detected, a corresponding manufacturing process can be executed without the need for manual input. Corresponding manufacturing processes can be stored, for example, for different configurations of submodules in the controller's memory, for example in a lookup table, and can be retrieved and executed by the controller when the corresponding configuration is detected.
[0036] According to a further embodiment, the device further comprises a monitoring module for monitoring the quality of the manufactured hybrid structure.
[0037] The monitoring module can be any suitable module for monitoring the quality of the manufactured structure. For example, it can be a module that monitors the layer thickness of the applied material, e.g., using appropriate sensors or probes. Another possibility is a camera module or any other suitable module. The monitoring module, like the cold gas spray head(s) and the processing module(s), can be a modular module that can be attached to the device. Different monitoring modules can also be used.
[0038] Furthermore, the monitoring module or one of the monitoring modules can include continuous monitoring of the contact with the base structure as well as the discharge quantities, so that the monitoring module can also be integrated into one of the other sub-modules (cold gas spray heads / processing modules) or, for example, into the control system.
[0039] According to a further embodiment, the device further comprises a robot arm, wherein the common unit is an end effector of the robot arm.
[0040] The device can comprise a robot arm or be the robot arm itself. The common unit is the end effector on the robot arm, to which various tools (in the form of cold spray nozzles and processing modules) can be attached. The robot arm then moves along the corresponding path over the substrate during production and performs the corresponding production steps. The controller can be part of the robot arm itself or can be mounted externally in a larger device or production system that includes the robot arm.
[0041] According to a second aspect, a method for manufacturing a hybrid structure using a device described above is provided. The method comprises, in a first step, loading a machining program into the device. In a second step, the method comprises positioning the common unit in an initial position. In a third step, the method comprises applying a first layer to a carrier material with the cold gas spray head. In a fourth step, the method comprises pre-machining, before starting the third step, a component on which the hybrid structure is formed, or applying a second layer or post-machining the first layer after completion of the third step with the machining module.
[0042] The device may be designed according to any of the previously described embodiments.
[0043] The machining program comprises the manufacturing process or the steps of the manufacturing process and can, for example (in the first step), in corresponding embodiments, be automatically loaded from a memory of the controller when corresponding identifier tags are detected, as described above. However, in other embodiments, the machining program can also be loaded manually by an operator or automatically by a manufacturing system that includes the device.
[0044] In the second step, the combined unit, which comprises at least one cold gas spray head and a processing module, is brought into an initial position above the carrier material, for example above a circuit board to which conductor tracks are to be applied. Then, in the third step, the cold gas spray head begins applying the first layer to the carrier material (for example the circuit board). The cold gas spray head can, for example, apply an electrically conductive material in the form of conductor tracks to the carrier material. For this purpose, the combined unit is guided along a predefined path over the carrier material. However, full-surface, closed layers can also be applied, for example by the combined unit spraying adjacent tracks one after the other.
[0045] The fourth step, although referred to here as the fourth step, does not necessarily take place after the third step. Rather, the fourth step is carried out essentially at the same time, immediately before, or immediately after the third step, and relates to a work step with the processing module. The terms “immediately before” or “immediately after” are always to be seen in relation to a specific point on the carrier material or in relation to the processing of this point with the corresponding module. The cold gas spray head or heads and the processing module(s) are operated simultaneously at least for a time, but cover a specific point on the carrier material one after the other, so that the sub-module further forward in relation to the predefined path processes a corresponding point on the carrier material before a sub-module further back in relation to the path.When the machining module performs a pre-processing step, the machining module is generally mounted upstream of the cold gas spray head in the common unit with respect to the predefined path, allowing it to machine every point along the predefined path first (while operating simultaneously with the cold gas spray head). When the machining module performs a post-processing step, the machining module is generally mounted downstream of the cold gas spray head in the common unit with respect to the predefined path, allowing it to machine every point along the predefined path after the cold gas spray head (while operating simultaneously with the cold gas spray head).
[0046] For example, if the device contains two processing modules, one for pre-processing and one for post-processing, the pre-processing module, the cold gas spray head, and the post-processing module can be arranged in a line within the common unit. The pre-processing module can, for example, be a grinding unit for pre-smoothing the support unit. The cold gas spray head then applies a desired material, and the post-processing module can, for example, apply an electrically insulating sealant. However, this is merely an example; other modules and sequences are also possible.
[0047] In summary, the invention provides a device and a method for manufacturing hybrid structures that enable the rapid, simultaneous execution of multiple process steps on a substrate. This is made possible, in particular, by the absence or at least significantly reduced thermal input into the substrate through the use of a cold gas spray nozzle. Furthermore, the device and method are modular and easily adaptable to changing requirements and enable a significant reduction in process times, since the substrate does not need to be de-synchronized after the application of a first layer and transferred to another device for subsequent steps.
[0048] BRIEF DESCRIPTION OF THE CHARACTERS
[0049] The following examples are described in more detail with reference to the accompanying drawings. The illustrations are schematic and not to scale. Like reference numerals refer to like or similar elements. They show:
[0050] Fig- 1 A schematic representation of a cold gas spray head
[0051] Fig- 2 A schematic representation of a device for manufacturing hybrid structures in a configuration as a robot arm with an end effector as a common unit.
[0052] Fig. 3 A flowchart of a method for manufacturing a hybrid structure. DETAILED DESCRIPTION OF EMBODIMENTS
[0053] Fig. 1 shows a schematic representation of a prior art cold gas spray head 11. The cold gas spray head 11 comprises a heater 11a (here in the form of a heating coil) in a housing 11b between a gas inlet 11c and a cooled nozzle 11d (e.g., a DeLaval nozzle). A highly compressed gas (e.g., nitrogen), which enters through the gas inlet 11c, is heated by the heater 11a and thereby accelerated toward the nozzle 11d. A material powder can be introduced into the nozzle 11d via a powder inlet 11e and is accelerated by the highly compressed gas. When the accelerated particles of the material powder emerge from the nozzle 1 Id and impact a surface of a carrier material 18, the particles deform plastically and form a corresponding first layer 20 (applied material 19) on the carrier material 18. The cold gas spray head is guided laterally over the carrier material 18 along a direction of movement 21.If a continuous first layer is to be formed, the cold gas spray head can apply parallel lines of deposited material 19 in the same manner. The deposited material 19 can be, for example, an electrically conductive material, and the carrier material 18 can be, for example, a circuit board on which conductor lines are to be applied.
[0054] Fig. 2 shows a schematic representation of an apparatus 10 for manufacturing hybrid structures according to the disclosure. The apparatus 10 is embodied here as a robot arm 17 and comprises a common unit 13, or an end effector 13, with a cold gas spray head 11 and a processing module 12. A controller 14, such as a general-purpose computer with a CPU and memory components, is functionally connected to the robot arm 17 and controls its operation and, through it, also the operation of the end effector 13, or the cold gas spray head 11, and the processing module 12.
[0055] The cold gas spray head 11 and the processing module 12 together form the
[0056] End effector 13 (i.e., the common unit 13, as described above). The cold gas spray head 11 comprises a heater 11a, a housing 11b, a gas supply 11c, a cooled nozzle 11d, and a powder supply 11e, as described above with reference to Fig. 1. An exhaust 22 is mounted around the exit area of the nozzle 11d to exhaust excess material.
[0057] In the illustrated configuration, the processing module 12 is designed as a post-processing module, in particular as a sealing unit for applying a seal. In other embodiments, however, the processing module 12 can also be, for example, a pre-processing module (e.g., a grinding unit, a milling unit, a honing unit) or a laser module (both for pre-processing the carrier material and for post-processing the applied material, for example, in laser sintering processes or similar processes). Furthermore, as described above, additional processing modules 12 or additional cold gas spray heads 11 can also be part of the end effector 13 in order to perform further pre-processing or post-processing steps or to apply additional layers, for example, made of other materials. The processing module can perform both deposition and removal steps.For example, the processing module can also grind a previously applied layer smooth before the next layer is applied.
[0058] A carrier material 18, such as a circuit board, is held on a holding structure 23. The robot arm 17 operates the end effector 13 and guides it along the direction of movement 21 over the carrier material 18, with the cold gas spray head 11 and the processing module 12 operating simultaneously. The cold gas spray head 11 can thus, for example, apply a metallic, electrically conductive material in the form of conductor tracks to the carrier material 18, which is then immediately over-sprayed with a seal in one go by the processing module 12. However, this is only an example. In other configurations, the device 10 can also be used for other applications, e.g. for building a layered structure such as a sandwich structure or for forming battery layers with a thin metal layer with an overlying insulator layer. Furthermore, the device can be used for an AFP process (English:The end effector 13 can be configured using automated fiber placement (AFP) to produce two layers simultaneously. However, these are only a few non-limiting examples. If a continuous material layer is to be applied, the end effector 13 can also be guided, for example, in parallel paths over the carrier material 18.
[0059] Fig. 3 shows a flowchart of an exemplary method 100 for manufacturing a hybrid structure using a device 10 disclosed herein, for example, the device 10 of Fig. 2. In a first step 110, a machining program is loaded into the device 10. This can be done, for example, by manual user input into the controller 14 or automatically, for example, by the controller 14 recognizing a configuration of the common unit 13, for example, based on RFID tags, as described above.
[0060] In step 120, the common unit 13, which has at least one cold gas spray head
[0061] 11 and at least one processing module 12, is brought into an initial position above the carrier material.
[0062] The steps 125, 130, 136 and 135 can take place essentially simultaneously, since, as described above, they are carried out in one go by the movement of the common unit 13 with the corresponding equipment of cold gas spray heads 11 and processing modules
[0063] 12 along the movement path 21. In step 125, the carrier material 18, or, if another layer was previously applied onto which a further layer is now applied, the previous layer, is pre-processed. The pre-processing 125 can, for example, consist of grinding by a corresponding processing module. At the same time, in step 130, a first layer, or in step 135 a second layer (if a first layer was previously applied, for example by another cold gas spray head 11 in the common unit 13) is applied, and in step 136 the first layer is post-processed. The post-processing can, for example, take the form of applying a sealant or changing the material properties of the material applied by the cold gas spray head 11, for example by using a heat or laser unit or any other suitable unit.
[0064] Steps 125, 130, 136, and 135 are performed simultaneously, but at slightly offset points on the carrier material 18. In this sense, the term "simultaneous" does not refer to simultaneous execution of the respective steps at a single point on the carrier material, but rather to simultaneous execution with respect to the entire component. The temporal sequence of the steps at each point on the movement path 21 is slightly offset and is defined by the arrangement of the individual sub-modules 11, 12 in the common unit 13, as described above. The method ends at 140 and can be repeated if necessary. Optionally, at the same time as steps 125, 130, 136, and 135, residual material can be suctioned away by suction devices 22 (Fig. 2) attached to the corresponding sub-modules.
[0065] Additionally, it should be noted that "comprising" or "having" does not exclude other elements or steps, and "a" or "an" does not exclude a plurality. Furthermore, it should be noted that features or steps described with reference to one of the above embodiments may also be used in combination with other features or steps of other embodiments described above. Reference signs in the claims are not to be considered as limitations.
[0066] LIST OF REFERENCE SYMBOLS
[0067] 10 Device for manufacturing hybrid structures
[0068] 11 Cold gas spray head
[0069] 11a Heating
[0070] 11b Housing
[0071] 11c Gas supply
[0072] 11 d cooled nozzle, DeLaval nozzle
[0073] I the powder feed
[0074] 12 Editing module
[0075] 13 common unit, end effector
[0076] 14 Control
[0077] 15 Identifier tag, RFID tag
[0078] 16 Monitoring module
[0079] 17 robot arms
[0080] 18 Carrier material
[0081] 19 applied material 0 first layer 1 movement path 2 suction 3 support structure
[0082] 30 second shift
[0083] 100 procedures
[0084] 110 Loading a machining program
[0085] 120 Positioning the end effector in an initial position
[0086] 125 Pre-processing a component
[0087] 130 orders of a first shift
[0088] 135 orders of a second shift
[0089] 136 Reworking the first layer
[0090] 140 End of the procedure
Claims
Patent claims 1. A device (10) for manufacturing hybrid structures, comprising: a cold gas spray head (11); a processing module (12); and a controller (14); wherein the cold gas spray head (11) and the processing module (12) are arranged in a common unit (13); wherein the controller is configured to control the operation of the cold gas spray head (11) and the processing module (12) such that a first work step is carried out by the cold gas spray head (11) and a second work step is carried out by the processing module (12), wherein the first work step and the second work step are initiated sequentially or simultaneously.
2. Device (10) according to claim 1, wherein the processing module (12) is an applying module for performing an applying work step, or an ablating module for performing an ablating work step.
3. Device (10) according to claim 2, wherein the processing module (12) is one of a sealing unit for applying a seal, a laser unit, a grinding unit, a milling unit and a honing unit.
4. Device (10) according to claim 1, wherein the processing module (12) is a second cold gas spray head.
5. Device (10) according to one of the preceding claims, further comprising a suction device which is arranged in the common unit (13) and which is configured to suck out excess working material from at least one working step.
6. Device (10) according to one of the preceding claims, wherein the processing module (12) is modularly replaceable and comprises an identifier tag (15) for identifying a type of the processing module (12) by the controller (14).
7. Device (10) according to claim 6, wherein the controller (14) is configured to carry out a manufacturing process depending on the type of the processing module (12).
8. Device (10) according to one of the preceding claims, further comprising a monitoring module (16) for monitoring the quality of the manufactured hybrid structure.
9. Device (10) according to one of the preceding claims, further comprising a robot arm (17), wherein the common unit (13) is an end effector (13) of the robot arm (17).
10. A method (200) for manufacturing a hybrid structure using a device (10) according to any one of the preceding claims, wherein the method (200) comprises the following steps: In a first step (110), loading a machining program into the device (10); In a second step (120), positioning the common unit (13) in an initial position; In a third step (130), applying a first layer (20) to a carrier material with the cold gas spray head (11); and In a fourth step (125, 135, 136), pre-processing (125), before starting the third step (130), of the carrier material (18) on which the hybrid structure is formed, or applications (135) of a second layer (30) or post-processing (136) of the first layer (20), after completion of the third step (130), with the processing module (12).