Method for fabricating a composite component from a first component and a second component

Abstract

The invention relates to a method for fabricating a composite component from at least a first component (4) and a second component (6). According to the invention, the method comprises the following steps: providing a first component (4), wherein the first component (4) comprises or consists of a microcellular elastomer, providing a second component (6), wherein the second component (6) comprises or consists of a thermoplastic polymer, extruding the second component (6), and applying a layer (8) of the extruded second component (6) onto the first component (4) by means of an application nozzle (18).

Description

[0001] Method for fabricating a composite component from a first component and a second component

[0002] The present invention relates to a method for fabricating a composite component from at least a first component and a second component, the method comprising: providing a first component, wherein the first component comprises or consists of a microcellular elastomer, and providing a second component, wherein the second component comprises or consists of a thermoplastic polymer. The present invention furthermore relates to a composite component and an additive manufacturing device for manufacturing a composite component.

[0003] The fabrication of composite components comprising a first microcellular elastomer component and a second thermoplastic polymer component is complex and can be realised by means of bonding the two components or an injection moulding process.

[0004] When producing prototypes of composite components during product design development stages, it is a major aim to fabricate the composite components in a similar way than envisaged for large-scale production processes. However, with regard to bonding, this process is unsuitable for large-scale production and can thus not be utilized to gain manufacturing experiences for a large-scale production. Injection moulding can in principle be used for small and large-scale production processes; it is however expensive for small quantities and prototypes because each adjustment in the composite component design requires a tool change that is associated with time effort and costs. Thus, injection moulding is typically not economically beneficial for fabricating small quantities and prototypes of composite components.

[0005] It was therefore an object of the invention to provide an alternative method for fabricating a composite component in particular for small series and prototype fabrication. Specifically, it was an object of the invention to provide a method that ensures that the components of the composite component are firmly connected to each other, while at the same time the design of the composite component can be adjusted without requiring substantial tool amendments.

[0006] The invention achieves the object of the invention in a method with the steps: extruding the second component, and applying a layer of the extruded second component onto the first component by means of an application nozzle. By extruding and applying a layer of the second component onto the first component, it is ensured that the two components are firmly connected, wherein the shape of the layer can be adjusted in order to form the geometry of the second component as required. The method reduces the costs for the fabrication of small series and prototypes. Furthermore, the design process of such a composite component could be supported directly with real components, wherein shorter reaction times to customer requests can be achieved. In turn, a competitive advantage can be achieved. Although the method is particularly beneficial for prototype production conducted before starting a large-scale series, and for the production of small series itself, the method may also be beneficial for fabricating large-scale series of composite components.

[0007] According to an embodiment, the application nozzle is an application nozzle of an additive manufacturing device, in particular a Fused Filament Fabrication additive device, and wherein the second component is applied onto the first component utilizing the additive manufacturing device. With the help of the additive manufacturing device, the second component can be “printed” on the first component in the required shape and form. The use of Fused Filament Fabrication devices, that are readily available on the market, reduces investment costs and development efforts. When using a Fused Filament Fabrication device, the thermoplastic polymer of the second component may be provided as filament which is easy to handle and may also be exchanged easily. The use of said additive manufacturing device ensures that the prototypes can be designed with a high regard of flexibility and low turnaround times and costs.

[0008] According to another embodiment, the application nozzle contacts the first component during application of the first layer in order to force the extruded second component at least partially into the first component. In this way, adhesion between the first component and the second component is achieved on the one hand by means of mechanical bonding and on the other hand by means of chemical bonding. In other words, the thermoplastic polymer is at least partially injected into the microcellular elastomer so as to establish a mechanical bonding between the components. A top portion of the first layer establishes a chemical bonding with the microcellular elastomer. In this way, the first component and the second component are firmly connected to each other without requiring additional bonding steps.

[0009] According to an embodiment, the application nozzle immerses into the first component by an immersion depth during application of the first layer, in particular wherein the immersion depth is in the range of 0,1 mm to 2 mm or 1 % to 30% of a total height of the first component. In general, the immersion depth can be chosen based on the Shore hardness of the first component, namely the microcellular elastomer. The given range has been found to be beneficial to ensure that both components are firmly connected and established both, a mechanical bonding and a chemical bonding.

[0010] According to another embodiment, the layer is a first layer and wherein the second component is applied onto the first component in at least a second layer, the second layer resting upon the first layer. In particular, the second layer is applied to the first layer without contacting the first component. This means, that the second layer is preferably applied only onto the first layer. According to one embodiment, further layers are applied upon the second layer, wherein the layers are provided on top of each other. In this way, the different layers may form a geometric shape of the second component.

[0011] According to one embodiment, the first layer and / or the second layer and / or further layers comprise a layer height of 0,05 mm to 0,4 mm, preferably 0,2 mm to 0,3 mm. The mentioned height-range has been found to be beneficial for printing a thermoplastic polymer onto a microcellular elastomer. According to one embodiment, the microcellular elastomer of the first component comprises or consists of a microcellular polyurethane, in particular a microcellular polyurethane foam. These microcellular polyurethane foams provide beneficial damping properties.

[0012] Microcellular in this context means that the cells preferably have a diameter of 0.01 mm to 0.5 mm, especially preferably from 0.01 mm to 0.15 mm.

[0013] Particular preference is given to microcellular polyurethane elastomers which, in a preferred embodiment, have a density in accordance with DIN 53420 of from 200 kg / m3to 1 ,100 kg / m3, preferably from 300 kg / m3to 800 kg / m3. Such microcellular polyurethane elastomers are also referred to as volume-compressible material (also: volume- compressible material of construction). Volume-compressible materials such as the abovementioned have the particular advantage that in comparison with other materials such as rubber they have extremely high capability for elastic change of shape together with high durability.

[0014] The production process usually takes place via reaction of isocyanates with compounds reactive toward isocyanates.

[0015] Microcellular polyurethane is usually produced in a mold in which the reactive starting components are reacted with one another. Molds that can be used here are generally conventional molds, for example metal molds, which by virtue of their shape ensure that the first element has the inventive three-dimensional shape. In one embodiment, a foaming mold is used to produce the first element. The manufacturing process can by way of example use water-jet cutting.

[0016] The microcellular polyurethane is the reaction product of a diisocyanate, a polyol and water. The diisocyanate is preferably selected from the group 1 ,4-paraphenylene diisocyanate (PPDI), 1 ,4-cyclohexane diisocyanate, 4,4'-diphenylmethane diisocyanate, 3,3'- dimethylbiphenyl-4,4'-diisocyanate and 1 ,5-naphthylene diisocyanate, or a mixture thereof. More preferred the diisocyanate is selected from 4,4'-diphenylmethane diisocyanate and 1 ,5-naphthylene diisocyanate, or is a mixture thereof. Most preferred the diisocyanate is 1 ,5-naphthylene diisocyanate. The polyol is preferably a difunctional polyol. The number average molecular weight of the polyol preferably is between 0.5 x 103g / Mol and 10 x 103g / Mol, more preferably between 0.6 x 103g / Mol and 6 x 103g / Mol, more preferably between 0.7 x 103g / Mol and 4 x 103g / Mol,.

[0017] The number average molecular weight Mn in the context of this invention preferably is determined by gel permeation chromatography, more preferably according to DIN EN ISO 13885-2:2020; whereas dimethylformamide (DMF) is used as solvent.

[0018] The polyol of the microcellular polyurethane preferably is a polyester diol or a polyether diol, or a mixture thereof. The polyether diol preferably is a polymer diol based on ethylene oxide, propylene oxide, tetrahydrofuran, or is a mixture thereof. More preferred the polyether diol is polytetrahydrofuran (PTHF).

[0019] The polyester diol of the microcellular polyurethane preferably is the reaction product of a dicarboxylic acid and a diol.

[0020] A preferred di-carboxylic acid is one of the C4 to C12 dicarboxylic acids, or a mixture thereof. A preferred diol is one of C2 to C14 diol, or a mixture thereof. More preferably the C4 to C12 dicarboxylic acid is an aromatic dicarboxylic acid or is an aliphatic dicarboxylic acid, or a mixture thereof.

[0021] Preferably the aliphatic dicarboxylic acid is selected from succinic acid, glutaric acid, adipic acid, suberic acid, azelaic acid and sebacic acid, or is a mixture thereof.

[0022] Preferably the aromatic dicarboxylic acid is selected from phthalic acid, isophthalic acid and terephthalic acid, or is a mixture thereof.

[0023] More preferably, the dicarboxylic acid is selected from the group consisting of succinic acid, glutaric acid, adipic acid, suberic acid, phthalic acid, isophthalic acid and terephthalic acid, or is a mixture thereof.

[0024] More preferably, the dicarboxylic acid is selected from the group consisting of adipic acid, suberic acid and phthalic acid, or is a mixture thereof. Most preferred the dicarboxylic acid is adipic acid.

[0025] The diol of the polyester of the microcellular polyurethane being an the reaction product of a dicarboxylic acid and a diol preferably is selected from ethylene glycol, 1 ,4-butanediol, 1 ,6-hexanediol, 2-methyl-1 ,3-propanediol, 3-methyl-1 ,5-pentanediol, 2,2-dimethylpropane- 1 ,3-diol, or is a mixture thereof.

[0026] In preferred embodiments of the microcellular polyurethane additionally blowing agents are used. For example low-boiling liquids that evaporate under the influence of the exothermic polyaddition reaction of the polyurethane.

[0027] Preferably auxiliaries are use when producing the microcellular polyurethane. These include, for example, surface-active substances, foam stabilizers, cell regulators, fillers, flame retardants, nucleation retardants, stabilizers, microbial inhibitors, lubricants and demolding aids, dyes and pigments.

[0028] The microcellular polyurethane is preferably produced by the prepolymer process. This means, that the diisocyanate is either reacted with the entire amount of the polyol before adding the other ingredients, containing water, orthe diisocyanate is reacted with the major part of the polyol, preferably more than 50 weight %, before adding the remain of the polyol, containing water and if applicable the other ingredients.

[0029] According to an embodiment, the thermoplastic polymer of the second component comprises at least one of the following: polyamide, thermoplastic polyurethane, polypropylene, polyethylene.

[0030] The mentioned materials have been found to be beneficial for application on the first component and can be utilized for a filament-based additive manufacturing process.

[0031] Preferably, the thermoplastic polyurethane is the reaction product of the constituent components a diisocyanate, a polyol and a chain extender.Thisdiisocyanate preferably is selected from the group consisting of organic polyisocyanate, more preferred is an organic diisocyanate; further preferred the isocyanate is selected from the group consisting of aliphatic, cycloaliphatic, araliphatic and aromatic isocyanates, or is a mixture thereof. Aliphatic isocyanates are preferred when stability against electromagnetic waves e.g. light is of importance, whereas aromatic polyisocyanate is preferred when high mechanical strength of the thermoplastic polyurethane is required. More preferred the diisocyanate is selected from methylene diphenyl isocyanate (MDI), hexamethylene diisocyanate (HDI), and methylenedicyclohexyl diisocyanate (H12MDI), or is a mixture thereof; More preferably the diisocyanate comprises 2,2'- diphenylmethane diisocyanate, 2,4'- diphenylmethane diisocyanate or 4,4'-diphenylmethane diisocyanate, or a mixture thereof, especially preferred is 4,4'-diphenylmethane diisocyanateThe polyol for reacting the thermoplastic Polyurethan has on statistical average at least 1.8 and at most 2.4 Zerewitinoff-active hydrogen atoms. This number is also referred to as the functionality of the polyol. The functionality preferably is between 1 .8 and 2.2, further preferred 2,0. Preferably the polyol has a number average molecular weight between 0.5 x103g / mol and 8 x103g / mol, more preferably between 0.6 x 103g / mol and 6.0 x 103g / mol, even more preferred between 0.6 x 103g / mol and 3.0 x 103g / mol.

[0032] More preferred the polyol for the thermoplastic polyurethane comprises a polyol, selected from the group consisting of polyether diol, polyester diol and polycarbonate diol, or is a mixture thereof. A preferred polyether diol for reacting the thermoplastic polyurethane is selected from the group of poly-ethanediol, poly-1 ,3-propanediol and poly-1 ,4-butane diol, or a mixture thereof.

[0033] Particularly preferred is polytetrahydrofurane (PTHF), preferably having a number average molecular weight Mn 0.6 x 103 g / mol and 2,0 x 103 g / mol, more preferably between 0.7 x 103 g / mol and 1 ,3 x 103 g / mol, most preferred 1 ,0 x 103g / mol.

[0034] Preferred polyester polyols for reacting the thermoplastic polyurethane include the polymerization product of a lactone, preferably a polycaprolactone, and those obtained by the polymerization of a di-carboxylic acid with a polyhydric alcohol, or a mixture thereof.

[0035] The polycaprolactone preferably has a number average molecular mass between 0.7 x 103 g / mol and 2.5 x 103 g / mol.

[0036] In another preferred embodiment the polyester diol is obtained by polymerizing a dicarboxylic acid with a polyhydric alcohol. A preferred di-carboxylic acid is one of the C4 to C12 dicarboxylic acids, or a mixture thereof. A preferred polyhydric alcohol is one of C2 to C14 diol, or a mixture thereof. More preferably, the dicarboxylic acid is selected from the group consisting of succinic acid, glutaric acid, adipic acid, suberic acid, phthalic acid, isophthalic acid and terephthalic acid, or is a mixture thereof. Most preferred the dicarboxylic acid is adipic acid.

[0037] The polyhydric alcohol preferably is selected from 1 ,2 ethane diol, diethylene glycol, 1 ,4- butanediol, 1 ,5-pentanediol, 3-methyl-1 ,5-pentanediol, 1 ,6-hexanediol, 1 ,10-decanediol, 2,2-dimethyl-propane-1 ,3-diol, 1 ,3-propanediol, 2-methyl-1 ,3-propanediol and di-propylene glycol, or is a mixture thereof. More preferably, the polyhydric alcohol is selected from the group consisting of 1 ,2-ethane diol, diethylene glycol, 1 ,4-butanediol, 1 ,5-pentanediol, 1 ,6- hexanediol, 1 ,10-decanediol, or a mixture thereof. Most preferably, the diol is selected from the group consisting of 1 ,4-butanediol, a mixture of 1 ,2-ethane diol and 1 ,4-butanediol, or a mixture of 1 ,4-butanediol and1 ,6-hexanediol.

[0038] A preferred polycarbonate diol is an aliphatic polycarbonate diol, more preferably an OH- difunctional polycarbonate diol. More preferred the polycarbonate diol is based on 1 ,4- butanediol, 1 ,5-Pentanediol, 1 ,6-Hexanediol, and 3-Methylpentane-(1 ,5)-diol, or a mixture thereof. A more preferred polycarbonate diol is based on 1 ,4-butanediol, 1 ,5-pentanediol, 1 ,6-hexanediol, or a mixture thereof. Another preferred polycarbonate diol is based on a mixture of 1 ,4-butanediol and 1 ,6- hexanediol, a mixture of 1 ,5-pentanediol and 1 ,6-hexanediol, or is a polycarbonate diol based on 1 ,6-hexanediol, or is a mixture thereof.

[0039] The polycarbonate diol preferably has a number average molecular weight Mn between 1 x 103 and 5 x 103 g / mol, more preferred between 1 .4 x 103 g / mol and 3 x 103 g / mol, more preferred between 1 .8 x 103 g / mol and 2.2 x 103 g / mol, more preferred 2.0 x 103 g / mol.

[0040] The chain extender in the thermoplastic polyurethane preferably is aliphatic, araliphatic, aromatic, or cycloaliphatic, or is a mixture thereof The chain extender preferably has a molecular weight between 50 g / mol and 499 g / mol. Further preferred the chain extender comprises 2 to 10 carbon atoms in the alkylene radical, more preferably 3 to 8 carbon atoms, more preferably is an alkane diol. The alkane diol preferably has only primary hydroxyl groups. Particularly preferred the alkane diol is selected from 1 ,2-ethylene glycol, 1 ,3-propanediol, 1 ,4-butanediol, 1 ,6-hexanediol, hydroquinone bis (beta-hydroxyethyl) ether (HQEE), di-, tri-, tetra-, penta-, hexa-, hepta-, octa-, nona- or decaalkylene glycol, also preferred the corresponding oligo- and / or polyalkylene glycol, or is a mixture thereof.

[0041] More preferably the chain extender is selected from the group consisting of ethane diol, propane diol, butane diol, hexane diol, or is a mixture thereof , more preferably is selected from the croup consisting of 1 ,2-ethane diol, 1 ,3-propane diol, 1 ,4-butane diol, 1 ,6-hexane diol, or is a mixture thereof, more preferably the chain extender is selected from 1 ,4-butane diol and 1 ,3-propane diol, or is a mixture thereof, most preferably the chain extender is 1 ,4 butane diol.

[0042] In a very preferred embodiment, the thermoplastic polyurethane is the reaction product of 4,4'-diphenylmethane diisocyanate, polytetrahydrofuran and 1 ,4-butandiol. The polytetrahydrofuran (PTHF) in this thermoplastic polyurethane preferably has a molecular weight between 0.6 x 103 g / mol and 2.5 x 103 g / mol, more preferably between 0.8 x 103 g / mol and 1.2 x 103 g / mol , most preferably 1 .0 x 103 g / mol.

[0043] The thermoplastic polyurethane preferably has a Shore hardness between 80 Shore A and 80 Shore D. The Shore hardness preferably is measured according to DIN ISO 7619-1 : 2016. Very preferably the thermoplastic polyurethane has a Shore hardness between 58 and 90 Shore A, between 90 and 100 Shore A, or between 65 and 75 Shore D.

[0044] In a preferred embodiment an auxiliary or additive is comprised in the first and / or the second component. The auxiliary or additive is a single substance, or a mixture of at least two substances. In a preferred embodiment the auxiliary or additive is selected from the group consisting of a surface-active substance, a filler, a flame retardant, a nucleating agent, an oxidation stabilizer, a lubricating aid, a demolding aid, a dye, a catalyst, a pigment, an inorganic filler or an organic filler, a reinforcing agent, a plasticizer, an antistatic agent, a stabilizer, preferably a stabilizer against hydrolysis, light, heat or discoloration, or is a mixture thereof.

[0045] According to one embodiment, the second component is applied through the application nozzle with a volumetric flow rate of 0,5 mm3 / s to 25 mm3 / s. The mentioned flow rates have been found to be beneficial for applying a thermoplastic polymer on the microcellular elastomer.

[0046] According to one embodiment, the second component comprises a Shore hardness of 70 A - 90 D, in particular 85 A - 74 D. The mentioned Shore hardness range allows for a chemical and mechanical bonding between the microcellular elastomer of the first component and the thermoplastic polymer of the second component.

[0047] According to one embodiment, a surface of the first component, on which the first layer of the second component is applied, is planar. In this way, the additive manufacturing or 3-D- printing process can be beneficially applied to the first component, in particular the planar section of the first component.

[0048] In a further aspect, the invention relates to a composite component fabricated by a method according to any one of the preceding embodiments. Since the second component establishes both a mechanical and chemical bonding with the first component, also the composite component fabricated by a method according to invention comprises a unique structure that is different to composite components fabricated for example by bonding or injection moulding.

[0049] According to one embodiment, the composite component is a two-component damping element, in particular a spring support comprising a base and a receptacle spring, wherein the base comprises or consists of microcellular polyurethane and wherein the receptacle for the spring comprises or consists of thermoplastic polyurethane. Such a two-component damping element is one example of a composite component that can be fabricated with the method according to the invention. Prototypes of such a two-component damping element can be beneficially fabricated with high flexibility with regard to design, low turnaround times and low costs.

[0050] The composite component according to the invention utilizes the same advantages and preferred embodiments as the method and vice versa. Preferred embodiments of the method are thus at the same time preferred embodiments of the composite component of the invention, and vice versa. In a further aspect, the invention also relates to an additive manufacturing device for manufacturing a composite component, comprising an application nozzle and a data processing device, the data processing device comprising means for carrying out the method of any one of the preceding embodiments. The additive manufacturing device according to the invention utilizes the same advantages and preferred embodiments as the method and the composite component of the invention. Preferred embodiments of the method and the composite components are thus at the same time preferred embodiments of the additive manufacturing device, and vice versa.

[0051] For a more complete understanding of the invention, the invention will now be described in detail with reference to the accompanying drawings. The detailed description will illustrate and describe what is considered as a preferred embodiment of the invention. It should of course be understood that various modifications and changes in form or detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention may not be limited to the exact form and detail shown and described herein, nor to anything less than the whole of the invention disclosed herein and as claimed hereinafter.

[0052] Further, the features described in the description, the drawings and the claims disclosing the invention may be essential for the invention considered alone or in combination. In particular, any reference signs in the claims shall not be construed as limiting the scope of the invention. The wording “comprising” does not exclude other elements or steps. The wording “a” or “an” does not exclude a plurality.

[0053] This invention will now be described with reference to the accompanying drawings which illustrate, by way of example and not by way of limitation, one of several possible embodiments of a method for fabricating a composite component as proposed herein, and wherein:

[0054] Fig. 1 shows a block diagram of a method according to the invention;

[0055] Fig. 2 shows a schematic overview of an additive manufacturing device applying the second component upon the first component;

[0056] Fig. 3 shows a schematic view of the method step of applying a first layer of the second component onto the first component; and

[0057] Fig.4 shows a schematic view of the method step of applying a second layer of the second component onto the first component. Figure 1 shows a method 100 for fabricating a composite component 2 as shown in figures 2 to 4 from at least a first component 4 and a second component 6, the method 100 comprising: providing 102 a first component 4, wherein the first component 4 comprises or consist of any microcellular elastomer, providing 104 a second component 6 wherein the second component 6 comprises or consists of a thermoplastic polymer, extruding 106 the second component 6 and applying 108 a layer 8 of the extruded second component 6 onto the first component 4 by means of an application nozzle 18.

[0058] The method is illustrated graphically in figure 2. Figure 2 shows an additive manufacturing device 16. The additive manufacturing device 16 comprises an application nozzle 18 which can be adjusted 3-dimensionally. The additive manufacturing device 16 is configured for extruding the second component 6, in particular a filament of the second component 6. The second component 6 is then applied on a layer-by layer basis and onto a first component 4 by means of the application nozzle 18.

[0059] The first component 4 comprises or consists of a microcellular elastomer. The second component 6 comprises or consists of a thermoplastic polymer. The additive manufacturing device 16 can be a Fused Filament Fabrication additive manufacturing device 16, as illustrated in figure 2. As shown on the top of figure 2, a filament of the second component 6 is provided to the nozzle 18. In figure 2, a first layer 8, a second layer 10 and further layers 12 have been applied to the first component 4. The layers comprise a layer height hiayer. The first component 4 has a total height htotai. The first component 4 and the layers 8, 10, 12 forming the second component 6 form the composite component 2.

[0060] In figure 3, the application of the first layer 8 onto the first component 4 is illustrated. The application nozzle 18 contacts the first component 4 during application of the first layer 8 in order to force the extruded second component 6 at least partially into the first component 4. In particular, the application nozzle 18 immerses into the first component 4 by an immersion depth d during application of the first layer 8. In this way, not only a chemical bonding between the first layer 8 of the second component 6 with the first component 4 is achieved, but also a mechanical bonding, since the thermoplastic polymer of the second component is partially injected into the microcellular elastomer of the first component 4. A chemical bonding area is marked with the reference sign 20, a mechanical bonding area with the reference sign 22. The first component 4 comprises a surface 14, which is substantially planar in order to allow for the application of the first layer 8 and the printing process as such.

[0061] Figure 4 illustrates the application of the second layer 10. The second layer 10 is applied only upon the first layer 8 and rests on the first layer 8. In other words, the second layer 10 and all further layers are applied without contacting the first component 4. Also, the application nozzle 18 does not contact or even immerse into the first component 4. This is only conducted for the first layer 8. The first layer 8 and the second layer 10 form a leap height hieap. The microcellular elastomer of the first component 4 comprises a microcellular polyurethane, in particular a microcellular polyurethane foam. The thermoplastic polymer of the second component 6 comprises at least one of the following: polyamide, thermoplastic made of polyurethane, polypropylene, polyethylene. The second component 6 is applied through the application nozzle 18 with a volumetric flow rate of 0,5 mm3 / s to 25 mm3 / s.

[0062] With the help of the illustrated method 100, the microcellular elastomer first component 4 and the thermoplastic polymer second component 6 are firmly connected, wherein the additive manufacturing process allows for a high design flexibility, low turnaround times and low production costs for fabricating such a composite component 2.

[0063] List of references

[0064] 2 composite component

[0065] 4 first component comprising microcellular elastomer

[0066] 6 second component comprising thermoplastic polymer

[0067] 8 first layer

[0068] 10 second layer

[0069] 12 further layers

[0070] 14 surface of the first component

[0071] 16 additive manufacturing device

[0072] 18 application nozzle

[0073] 20 chemical bonding area

[0074] 22 mechanical bonding area

[0075] 100 method

[0076] 102 providing a first component

[0077] 104 providing a second component

[0078] 106 extruding the second component

[0079] 108 applying the extruded second component onto the first component d immersion depth htotai tota I h e ig ht of th e f i rst co m po n e nt hiayer layer height hieap leap height

Claims

Claims1. Method (100) for fabricating a composite component (2) from at least a first component (4) and a second component (6), the method (100) comprising: providing (102) a first component (4), wherein the first component (4) comprises or consists of a microcellular elastomer, providing (104) a second component (6), wherein the second component (6) comprises or consists of a thermoplastic polymer, extruding (106) the second component (6), and applying (108) a layer (8) of the extruded second component (6) onto the first component (4) by means of an application nozzle (18).

2. Method (100) according to claim 1 , wherein the application nozzle (18) is an application nozzle (18) of an additive manufacturing device (16), in particular a Fused Filament Fabrication additive manufacturing device (16), and wherein the second component (6) is applied onto the first component (4) utilizing the additive manufacturing device (16).

3. Method (100) according to any one of the preceding claims, wherein the layer (8) is a first layer, and wherein the application nozzle (18) contacts the first component (4) during application of the first layer (8) in order to force the extruded second component (6) at least partly into the first component (4).

4. Method (100) according to claim 3, wherein the application nozzle (18) immerses into the first component (4) by an immersion depth (d) during application of the first layer (8), in particular wherein the immersion depth (d) is in the range of 0,1 mm to 2 mm or 1 % to 30 % of a total height (htotai) of the first component (4).

5. Method (100) according to any one of the preceding claims, wherein the layer (8) is a first layer (8) and wherein the second component (6) is applied onto the first component (4) in at least a second layer (10), the second layer (10) resting upon the first layer (8).

6. Method (100) according to claim 5, wherein the second layer (10) is applied to the first layer (8) without contacting the first component (4).

7. Method (100) according to any one of the preceding claims, wherein the layer (8) is a first layer (8), and wherein the first layer (8) and / or the second layer (10) and / or further layers (12) comprise a layer height (hiayer) of 0,05 mm to 0,4 mm, preferably 0,2 mm to 0,3 mm.

8. Method (100) according to any one of the preceding claims, wherein the microcellular elastomer of the first component (4) comprises a microcellular polyurethane, in particular a microcellular polyurethane foam.

9. Method (100) according to any one of the preceding claims, wherein the thermoplastic polymer of the second component (6) comprises at least one of the following: polyamide, thermoplastic made of polyurethane, polypropylene, polyethylene.

10. Method (100) according to any one of the preceding claims, wherein the second component (6) is applied through the application nozzle (18) with a volumetric flow rate of 0,5 mm3 / s to 25 mm3 / s.11 . Method (100) according to any one of the preceding claims, wherein the second component (6) comprises a Shore hardness of 70 A - 90 D, in particular 85 A - 74 D.

12. Method (100) according to any one of the preceding claims, wherein a surface (14) of the first component (4) on which the first layer (8) of the second component (6) is applied, is planar.

13. Composite component (2) fabricated by a method (100) according to any one of the preceding claims.

14. Composite component (2) according to claim 13, wherein the composite component (2) is a two-component damping element, in particular a spring support comprising a base and a receptacle for the spring, wherein the base comprises or consists of microcellular polyurethane and wherein the receptacle for the spring comprises or consists of thermoplastic polyurethane.

15. Additive manufacturing device (16) for manufacturing a composite component (2), comprising an application nozzle (18) and a data processing device, the data processing device comprising means for carrying out the method (100) of any one of claims 1-12.

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