Production process for overmolding a component with a rod-shaped metal body

Abstract

The invention relates to a process for producing a component (1), for example a rotor, comprising a rod-shaped metal body (3), for example a rotor shaft, consisting of the following process steps: - providing the rod-shaped body (3); - introducing elevations or depressions (10-10") so as to form a surface structuring on a surface section of the rod-shaped body (3); - overmolding the surface section of the rod-shaped body (3) by means of a plastics material so as to form a connecting body (6), for example a rotor hub. The overmolding of the surface section of the rod-shaped body (3) produces a connection between the rod-shaped body (3), for example the rotor shaft, and the connecting body (6), for example the rotor hub. A functional device (2), for example consisting of a magnetic coil or permanent magnets (7, 7') with a back iron (8), is optionally provided and positioned prior to the overmolding with plastics material.

Description

[0001] Manufacturing method for overmolding a component with a rod-shaped metal body

[0002] The invention relates to a method for producing a component comprising a rod-shaped metallic body. Corresponding methods for producing a rod-shaped metallic body, for example, provided with a functional device, are known in principle from the prior art. For example, it is known to overmold a rod-shaped body with a plastic component during an injection molding process. Typically, the functions of the component to be manufactured are realized by the molded-on plastic component itself and / or by the rod-shaped body. However, this leads to a limitation of the functionalities that can be realized with the component.

[0003] The invention is based on the object of specifying a method which, in particular with regard to a simple, rapid and cost-effective measure, enables the production of a component which comprises a rod-shaped metallic body and a functional device, which is characterized by robustness and by a multitude of possibilities for the realization of functionalities.

[0004] The object is achieved by a method for producing a component comprising a rod-shaped metallic body according to claim 1. The dependent claims relate to possible embodiments of the method. Furthermore, the object is achieved by a component according to claim 28 and by a device according to claim 29.

[0005] The invention relates to a method for producing a component, which in particular comprises a functional device and a rod-shaped metallic body. The method provides for the provision of a single-piece or multi-piece rod-shaped metallic body. Elevations and / or depressions are introduced into a surface section of the rod-shaped body in order to form a surface structuring on the surface section. Optionally, a functional device can be provided, which initially forms a body separate from the rod-shaped metallic body. In a further method step, the surface section of the rod-shaped body is encapsulated using a plastic material to form a connecting body, wherein the encapsulation of the surface section of the rod-shaped body creates a connection between the rod-shaped body and the connecting body.In other words, overmolding the surface section of the rod-shaped body creates a good mechanical connection, as the plastic material forms an intimate, i.e., positive, connection with the elevations and depressions of the surface structure. The molded plastic material can be arranged in the depressions and / or around the elevations, thus forming a resilient connection, also due to a large connection surface.

[0006] For example, the method can comprise providing a functional device, wherein a connection between the rod-shaped body and the functional device is created by overmolding the surface section of the rod-shaped body. By overmolding the rod-shaped body, a load-bearing connection can be created between the rod-shaped body and the functional device; for example, a rigid connection can be created between the rod-shaped body and the functional device by the connecting body. If the rod-shaped body is formed, for example, in several pieces, the at least two pieces to be assembled, in particular joined together, to form the rod-shaped body can be or have been connected to one another in a force-fitting and / or material-fitting and / or form-fitting manner before and / or during the overmolding of the surface section of the rod-shaped body to form the connecting body.

[0007] The functional device can comprise at least one functional element optimized for the intended application of the component, e.g., at least one magnetic active element and / or at least one bearing sleeve and / or at least one winding element. Thus, the functional device can optionally comprise, for example, an assembly of at least two functional elements or functional parts. For example, an additional functional element is attached, in particular mounted, to a first functional element.

[0008] The at least one functional element of the component designed as a magnetic element can, for example, be or comprise an element comprising a ferromagnetic material which itself has magnetic properties or is magnetizable. A magnetizable magnetic element can, for example, be an electrical coil. The magnetic element can also have a passive magnetic mode of action, i.e., the magnetic element itself does not generate a magnetic field, but a prevailing magnetic field can be permanently or temporarily influenced, e.g., amplified or directed, by the magnetic element. For example, at least one functional element can be designed as an iron element or an iron package comprising a group of iron elements. In general, at least one functional element designed as a magnetic element can be used which acts as a magnet (e.g.,Permanent magnet) or as a magnetizable element or as an element influencing a magnetic field. Because the at least one functional element is produced or provided separately from the rod-shaped body and separately from the connecting body or the overmolding of the rod-shaped body, the functional element can be designed almost freely with regard to its mechanical and / or chemical properties.

[0009] In an advantageous embodiment, the component is used as a component of an electrical machine, in particular an electric motor. The electric motor can be used, for example, for a secondary function of a vehicle, preferably a land vehicle, particularly preferably a passenger car or a commercial vehicle. An electric motor used for a secondary function in a vehicle fulfills a function that does not serve the purpose of traction or propulsion of the vehicle.

[0010] It is possible that, prior to overmolding the surface portion of the rod-shaped body to form the connecting body, a holding body is attached to at least one functional element of the functional device during a joining process. For example, prior to overmolding the surface portion of the rod-shaped body to form the connecting body, a holding body is injection-molded onto at least one functional element of the functional device by at least partially, preferably predominantly, particularly preferably completely, overmolding it with a plastic material. Thus, the holding body, as a component already defined in its shape, can be attached to the functional element by means of a force-fitting and / or material-fitting and / or form-fitting fastening before overmolding the surface portion. According to an exemplary embodiment, the holding body can be formed by at least partially overmolding the functional element.The holding body and the functional element can thus form components of the functional device. By overmolding a holding body onto at least one functional element of the functional device, the functional device can form a hybrid intermediate component and, as a hybrid intermediate component, can be connected to the rod-shaped body during the overmolding of the surface section of the rod-shaped body. The material used to form the holding body can be identical to or different from the material used to form the connecting body. Preferably, materials with a similar thermal expansion coefficient are selected as the plastic material used to form the holding body and the connecting body. For example, the difference in the thermal expansion coefficient is a maximum of 1.0%, preferably a maximum of 0.25%, particularly preferably a maximum of 0.10%, most preferably a maximum of 0.01%, further preferably a maximum of 0.001%.The holding body can, for example, have a holding function for another component (e.g., for at least one iron element). The holding body can, for example, be in the shape of a ring, in particular a closed ring. Thus, the holding body can delimit a radially inner cavity radially outward, in particular without gaps. The rod-shaped body and / or the connecting body can be arranged at least partially in such a cavity in the final assembly state.

[0011] It is possible for the component to be manufactured to react in a targeted manner, at least in sections, to magnetic influences during intended use. This can provide for at least one functional element to be designed as a magnetic element. Optionally, in addition to designing the at least one functional element as a magnetic element, an iron packet consisting of at least two iron elements can be at least partially overmolded during the at least partial overmolding of the at least one functional element to form a holding body. Instead of or in addition to the iron packet consisting of at least two iron elements, a magnetic flux-carrying element can be used, i.e. an element that reacts to a magnetic field. The holding body therefore holds the at least one magnetic element and the iron packet.This makes it possible to create an intermediate assembly comprising at least one magnetic active element, the iron package and the holding body. This intermediate assembly can then be connected to the rod-shaped body in a downstream overmolding process to form the connecting body by overmolding the rod-shaped metallic body. In other words, the holding body can form an assembly, in particular one that is fixed in itself, with the at least one magnetic active element and the iron package. This assembly can form a magnetic active device which, in a subsequent method step, is arranged in a defined alignment and / or positioning relative to the rod-shaped body, in particular to a shaft body, and is bonded to the rod-shaped body or shaft body during the overmolding of the surface section of the rod-shaped body or the shaft body using a plastic material to form the connecting body or a hub body.Shaft body is connected. Instead of the iron core, the holding body can also touch or at least partially surround at least one first functional element, a further functional element which is different from an iron core, in particular a functional element designed as a magnetic flux-carrying element, during the at least partial encapsulation of a first functional element. At least one iron element of the iron core can be designed, for example, as a sheet metal element. Alternatively or additionally, at least one iron element of the iron core can be designed as a sintered part. The iron element comprises at least iron as a component, e.g. the iron element is made of steel.

[0012] In an advantageous embodiment, it can be provided that an iron core comprising at least two iron elements and at least one functional element is fastened to the rod-shaped body without a holding body by forming the connecting body. For example, the connecting body can come into direct contact with a portion of at least one functional element and with a portion of the iron core, without any pre-fixing of the iron core to the at least one functional element via a holding body that later forms a component of the component.

[0013] The at least one functional element, in particular all functional elements of the rod-shaped metallic body provided with a functional device, and the holding body can, for example, be overmolded with plastic material to form the connecting body in such a way that the connecting body is in contact with the holding body and the at least one functional element. In other words, by means of the connecting body, not only a direct and / or exclusively via the

[0014] Connecting body connection of the rod-shaped body with the

[0015] functional device, but additionally a connection between the holding body and the functional element which is made directly via the connecting body. For example, at least one functional element can be connected in a touching manner to the holding body at a first connecting section and can be connected in a touching manner to the connecting body at at least one further connecting section. The connecting body can, for example, be in contact with the holding body and the at least one functional element and the iron core. Alternatively or additionally, for example, at least one functional element, in particular all of the functional elements, can have no direct contact with the connecting body and can be connected to the connecting body exclusively via the holding body and / or the iron core.

[0016] In an optional method step, the rod-shaped body and the holding body carrying at least one functional element can be arranged in a defined relative position, wherein the rod-shaped body is overmolded to form the connecting body after the defined relative positioning has been achieved. For this purpose, an injection molding tool used for an injection molding process forming the connecting body can be equipped with the rod-shaped body and the holding body carrying the at least one functional element before the injection molding process, wherein the injection molding is carried out after this event. The relative positioning of the functional element-holding body assembly and the rod-shaped body forms a cavity into which the plastic material is introduced.Any adverse tolerance effects of a functional device and / or a holding body and / or a rod-shaped body can be minimized by a targeted and, in particular, adapted relative positioning of the functional element-holding body assembly to the rod-shaped body.

[0017] By first creating a functional device with a holding device as a geometrically defined body by molding the holding device onto the functional device, and then specifically aligning the holding device-functional device assembly relative to the rod-shaped body, this relative alignment can be used to compensate for or reduce any differences in the holding device-functional device assembly and / or the rod-shaped body, particularly with regard to imbalance. Adjusting the relative alignment can also be used for components that do not form a holding body, so that a first functional device is aligned or positioned in a first relative orientation with respect to a first rod-shaped body and finally overmolded to form the connecting body.In a second injection molding process for forming a connecting body of a further component, a different relative alignment can be achieved compared to the corresponding part of a previously manufactured component, depending on a physical and / or chemical difference between the functional device and / or the rod-shaped body and the relative alignment used in the previously manufactured component. For example, depending on a difference in the imbalance behavior of a functional device and / or the rod-shaped body of a first component compared to the imbalance behavior of a functional device and / or a rod-shaped body of a further component, a different alignment or positioning of the holding device and / or the rod-shaped body can be adopted for the further component.

[0018] In a preferred embodiment, the introduction of elevations and / or depressions for forming the surface structuring into the rod-shaped body takes place by means of at least one laser beam. In other words, the metallic rod-shaped body can be exposed to a laser beam in order to achieve a target shape and / or target characteristic of the surface structuring. The rod-shaped body can be made, for example, of steel, in particular of hardened steel. As a material for the rod-shaped body, for example, stainless metal, e.g. a Ni-Cr-containing metal alloy, can be used. For example, a material is used for the rod-shaped body which has a hardness of 30 to 85 HRC, preferably of 45 to 75 HRC, particularly preferably of 50 to 70 HRC, most preferably of 55 to 65 HRC.The surface exposure of the metallic body to a laser beam can, for example, be carried out using the following laser parameters. When the metallic rod-shaped body is exposed to the at least one laser beam, a structuring can result which has micro- and macrostructure components or which has exclusively microstructure components or exclusively macrostructure components. Accordingly, the laser-assisted structuring which is formed here can have elevations and / or recesses in the micrometer range, i.e. in a range from 1.0 micrometer to 999 micrometers, or in a macrometer range, i.e. in a range greater than 999 micrometers. It is possible for the laser exposure to be carried out in such a way that no targeted or defined elevations and / or recesses are formed in the nanometer range, i.e. in the range of less than 1.0 micrometer.

[0019] The surface structuring can, for example, take the form of forming a plurality of partial surface sections, wherein the partial surface sections can have a straight line at least in sections, preferably predominantly, particularly preferably completely. For example, at least one partial surface section, in particular all partial surface sections of the rod-shaped body, can have a width of 0.02 mm to 1.0 mm, preferably from 0.05 mm to 0.60 mm, particularly preferably from 0.10 mm to 0.40 mm, most preferably from 0.15 mm to 0.30 mm, further preferably from 0.20 mm. For example, a surface structuring can be created which consists of at least two intersecting and / or crossing partial surface sections which at least in sections run in a straight line. For example,a cross is formed by two rectilinear partial surface sections intersecting at an angle of preferably 30° to 60°, particularly preferably 90°.

[0020] Alternatively or additionally, at least one partial surface section, in particular all partial surface sections of the rod-shaped body, can have a length of 0.25 mm to 2.0 mm, preferably from 0.35 mm to 1.4 mm, particularly preferably from 0.5 mm to 0.9 mm, most preferably 0.7 mm. Alternatively or additionally, a length-to-width ratio of at least one partial surface section, in particular of all partial surface sections, can be 1.75 to 5.5, preferably 2.5 to 4.5, particularly preferably 3.0 to 4.0, most preferably 3.1 to 3.8, further preferably 3.3 to 3.7.

[0021] Alternatively or additionally, the partial surface sections can be designed in such a way that they form a wave-like or zigzag pattern. In particular, a straight partial surface section forms a rising wave, and a subsequent partial surface section forms a descending wave, forming a wave shape.

[0022] It is also optionally possible for a minimum distance, in particular a minimum axial distance (ie a distance running along the axis of rotation of the rod-shaped body) between two adjacent partial surface sections to a width of the adjacent partial surface sections to have a ratio of at least 0.9, preferably 1.2, particularly preferably 1.35, most preferably 1.4, and / or a maximum ratio of 2.5, preferably 2.1, particularly preferably 1.8, most preferably 1.65, more preferably 1.5.

[0023] It is possible for the surface structuring to take the form of forming a plurality of partial surface sections, wherein the partial surface sections have or form a cross and / or star structure at least in sections, preferably predominantly, particularly preferably completely. Thus, for example, two, in particular each straight, partial surface sections can intersect or cross to form a cross and / or star structure. A cross structure can be created, for example, by crossing in particular two, preferably straight, lines traced by the laser on the surface of the shaft body, so that a partial surface section having a cross shape is formed. The star and / or cross structure can have the shape of a star or a cross when viewed from a top view of the rod-shaped body, i.e.in a consideration of a plane that is aligned parallel to the tangent of a round, in particular circular, rod-shaped metal body.

[0024] The surface structuring can, for example, be carried out in such a way that a first group of partial surface sections and at least one further group of partial surface sections are each formed in a row, in particular a straight row. In other words, three or more partial surface sections can be arranged as a group on a preferably straight line. The straight line can, for example, run parallel to the longitudinal axis of the rod-shaped body or have a screw-like or helical course around the longitudinal axis of the rod-shaped body, in particular with an at least partially, preferably predominantly, particularly preferably exclusively, constant pitch or constantly changing pitch or non-constant pitch.The helical course of the straight line on which a group of partial surface sections is arranged can enclose the circumference perpendicular to the longitudinal axis of the rod-shaped body at least once or it can not completely enclose the circumference perpendicular to the longitudinal axis of the rod-shaped body. The connecting body can, for example, completely encircle the rod-shaped body on its outer surface in at least one transverse plane. For example, the connecting body surrounds the rod-shaped body at least in sections in a sleeve-like or cylindrical manner. The connecting body has, for example, a receiving opening which receives the rod-shaped body at least in sections and surrounds its outer surface without gaps at least in one axial section. In other words, the contact surface of the connecting body with the rod-shaped body can have a circular-cylindrical shape, in particular a closed outer surface.

[0025] In general, the connecting body can be connected, in particular injection-molded, exclusively to the lateral surface of the rod-shaped body or exclusively to one end face of the rod-shaped body or to the lateral surface and the end face of the rod-shaped body via a surface structuring there.

[0026] For example, the partial surface sections of a group of partial surface sections that lie on a straight or odd line extend within an angular range a of a maximum of 350°, preferably a maximum of 280°, particularly preferably a maximum of 180°, most preferably a maximum of 90°, further preferably a maximum of 45°, viewed from the center of the rod-shaped body in the cross-sectional representation. Because the angle a has one of the values ​​mentioned, in particular a value of a maximum of 45°, in the event of plastic material being introduced and moved within a gap which is partially formed by the rod-shaped body, little disruptive influences, in particular little resistance, can be generated in the surface structuring during the encapsulation of the rod-shaped body. The encapsulation process of the rod-shaped body can therefore take place without any significant influence, despite the surface structuring being provided on the rod-shaped body.It is possible for a first group of partial surface sections, which are arranged on a first straight line, and a further group of partial surface sections, which are arranged on a further straight line, to have a constant distance. In other words, a first line, on which partial surface sections are arranged, can run equidistant from the at least one further straight line, on which in turn partial surface sections are arranged. Preferably, all straight lines run equidistant from their adjacent straight lines, with each straight line indicating a respective course of partial surface sections. In this case, a single, elongated partial surface section or a group consisting of at least two, preferably at least three, partial surface sections can lie on a straight line. Spaced-apart partial surface sections can, for example, be arranged in a row along a line of extension, e.g.a straight line, wherein the distance between a first extension line and an adjacent further extension line can be at least the maximum extension of a partial surface section transverse to its longitudinal extension line. The extension lines can, for example, be aligned parallel to the longitudinal axis of the shaft.

[0027] The surface structuring can, for example, be carried out in such a way that at least one group of partial surface sections, in particular at least two groups of partial surface sections, are arranged spirally or helically over the circumference of the shaft body. In other words, the partial surface sections are arranged helically in a direction along an outer circumferential surface of the rod-shaped body. For example, to form the helical shape of the partial surface sections, the rod-shaped body is rotated while elevations and / or depressions are being introduced to form the surface structuring on its surface section; in particular, the body is rotated while being subjected to a laser beam for this purpose. It is also possible for both the laser beam to be rotated or moved around the rod-shaped body and for the rod-shaped body to be rotated or moved relative to the laser beam.

[0028] In an optional method step, it can be provided that, before the rod-shaped body is overmolded to form the connecting body, a gap is formed at least between the rod-shaped body and the functional device, in particular at least between the rod-shaped body and the holding body, wherein, during the overmolded process of the rod-shaped body being overmolded to form the connecting body, the plastic material used for overmolded processing is introduced into the gap via at least one material strand along the longitudinal axis of the rod-shaped body. Preferably, the at least one material strand is introduced into the gap in such a way that it moves at least predominantly helically or screw-like along the longitudinal axis. This helical or screw-like movement along the longitudinal axis can, for example, have a constant pitch or a constantly changing pitch or a non-constant pitch.The gap can, for example, form an annular gap or a gap that essentially has the basic shape of a cylindrical sleeve. Preferably, at least two material strands can be introduced into the gap, in particular simultaneously, along the longitudinal axis of the rod-shaped body. For example, the at least two material strands are introduced into the gap via at least two injection openings / gating points of a tool mold and / or are formed within the gap by flow-standing and thus material-strand-forming geometries. It is also possible for three material strands to be introduced into the gap via flow-directing geometries and / or three gating points, which are placed in particular equidistant from adjacent gating points. The material strands can, for example, be introduced exclusively from a longitudinal side section of the rod-shaped body.

[0029] It is possible that before or during the overmolding of the rod-shaped body to form the connecting body, a gap is formed at least between the rod-shaped body and the functional device, wherein the plastic material used for overmolding is introduced into the gap from a starting point arranged in a first region, in particular end region, of the surface section of the rod-shaped body and moves within the gap along a longitudinal extent of the rod-shaped body to a second region, in particular end region, of the surface section of the rod-shaped body, wherein the elevations and / or depressions of the surface structuring on a longitudinal section of the rod-shaped body facing the first region, in particular end region, of the surface section have a stronger pronouncedness than the elevations and / or depressions of the surface structuring of a second region,In particular, the end region, facing the longitudinal section of the surface section. Due to the fact that the extent of the elevations and / or depressions, i.e., their maximum or average heights or depths or roughness values, decreases in the direction of movement of the plastic material moving in the gap during the overmolding process, reliable and consistent quality can be achieved across the production of a large number of components. As the plastic material continues to penetrate into the gap, the resistances for the plastic material generally increase, so that with the reduction in the extent of the elevations and / or depressions in the flow direction of the plastic material, a reduction in resistance occurs with regard to a resistance effect resulting from the interaction between the plastic material introduced into the gap and moving there and the surface structuring.can be achieved. For example, a decrease in pressure and thus in imaging accuracy may occur due to the plastic material progressively penetrating the gap. This can be compensated for by varying the shape of the elevations and / or depressions, in particular by decreasing the degree of the protrusions and / or depressions in the direction of flow.

[0030] In an optional method step, at least one functional element of a functional device, and in particular at least one iron core, can be inserted into a first tool part mold. Furthermore, a cavity is formed by attaching at least one second tool part mold to the at least one first tool part mold, and the functional element, in particular and additionally the iron core, is overmolded by filling the cavity with a plastic material to form the holding body. After moving the at least one second tool part mold to expose a receiving space formed or delimited by the holding body, the rod-shaped body can be inserted into the receiving space. In other words, the rod-shaped body can be inserted into the exposed section and / or fed via the exposed section.The first tool part is then closed by the second tool part or by at least one third tool part to form a second cavity adjacent at least to the rod-shaped body and the holding body, and the rod-shaped body is at least partially overmolded by filling the second cavity with a plastic material to form the connecting body. The at least one functional element of the functional device and optionally the iron package can preferably be attached to, e.g., in or on, a first tool part.

[0031] The plastic material of the connecting body and / or the plastic material of the holding body can, for example, be formed at least partially, preferably predominantly, particularly preferably entirely, from a thermoplastic or a thermosetting plastic. For example, an epoxy resin and / or a phenolic resin can be used as the plastic material. It is also possible to use a polyamide (PA), in particular a polyphthalamide (PPA), or a polyphenylene sulfide (PPS) as the plastic material for the connecting body and / or for the holding body. This allows, for example, a high degree of imaging accuracy to be achieved during the overmolding of the rod-shaped body.

[0032] In a preferred embodiment, a magnet can be used as at least one functional element of the functional device. In particular, the rod-shaped body can be used as the shaft of a rotor of an electric machine. Thus, the connecting body can form a hub element that connects the shaft to the at least one magnet.

[0033] In general, the rod-shaped body can be used, for example, as the shaft of a rotor of an electrical machine. Alternatively, the rod-shaped body can be used, for example, as a bearing element of a stator for supporting a rotor of an electrical machine, i.e., as the axis of a rotor.

[0034] It is possible for an electrical coil to be used as at least one functional element of the functional device. The rod-shaped body connected to the functional device designed as an electrical coil can be used as an axle for supporting a rotor or as a rotor shaft of an electrical machine.

[0035] As at least one functional element of the functional device, for example, a body forming a, in particular a closed, ring can be used. For example, the functional element can be designed as a bearing sleeve and / or as a bearing ring and / or as a contact element forming a valve plate section and / or as a gear. The component can, for example, form a valve, wherein a valve plate of the valve is formed by the functional device and the connecting body. In particular, a contact section of the valve contacting a valve seat can be designed as a functional device in the form of a contact element which creates a connection with the rod-shaped body during the encapsulation of the rod-shaped body by the connecting body. It is also possible for the component produced in the method described herein to form an armature of a magnetic system or a push rod.Alternatively or additionally, the rod-shaped element can be used as a guide rod, in particular for an anchor system. Preferably, the component produced by the method and / or the rod-shaped body and / or the functional device and / or the connecting body and / or the holding body can have a rotationally symmetrical shape. The rod-shaped element can, for example, be formed in one piece from a single metal body or in multiple pieces from at least two metal bodies.In the case of a rod-shaped element formed from at least two metal bodies, the at least two metal bodies can be connected to one another by a force-fitting and / or material-fitting and / or form-fitting connection; preferably, a force-fitting and / or material-fitting and / or form-fitting connection of the at least two metal bodies forming the rod-shaped body takes place before or during the overmolding of the surface section of the rod-shaped body by means of the plastic material to form a connecting body.

[0036] In addition to the method for producing a component, the invention also relates to a component having a functional device comprising at least one functional element and a rod-shaped body, wherein the component is produced using a method described herein. Furthermore, the invention relates to an apparatus for producing a component having at least one functional device comprising a functional element and a rod-shaped body, and is produced using a method described herein.

[0037] All advantages, details, designs and / or features of the component according to the invention are transferable or applicable to the method according to the invention and to the device according to the invention for producing a component and vice versa.

[0038] The invention is explained in more detail using exemplary embodiments in the drawings. In the drawings:

[0039] Fig. 1 is a schematic diagram in longitudinal section of a component according to an embodiment;

[0040] Fig. 2 is a schematic representation in longitudinal section of the component according to Figure 1 in a section plane rotated about the longitudinal axis relative to the section plane of Figure 1;

[0041] Fig. 3 is a perspective sectional view in longitudinal section of the component according to Figure 1;

[0042] Fig. 4 is a schematic diagram of a rod-shaped body according to an embodiment;

[0043] Fig. 5 is a schematic diagram of a side view of the rod-shaped body according to Figure

[0044] 4;

[0045] Fig. 6 is a schematic detailed representation of a surface structuring according to detail A of Figure 4;

[0046] Fig. 7 is a schematic representation of a component designed as a valve according to an embodiment;

[0047] Fig. 8 is a schematic representation of a surface structuring of a rod-shaped body according to an embodiment;

[0048] Fig. 9 shows a schematic diagram of method steps according to an embodiment; Fig. 10 shows a schematic diagram of method steps according to an embodiment;

[0049] Fig. 11 is a schematic representation of a component designed as a stator according to an embodiment;

[0050] Fig. 12 is a schematic representation of a gap space and a plastic material introduced into the gap space for overmolding the rod-shaped body according to an embodiment, as well as the pressure curve;

[0051] Fig. 13 is a schematic representation of a component designed as a stator according to an embodiment;

[0052] Fig. 14 is a schematic representation of a surface structuring formed on a round Meta II body according to an embodiment;

[0053] Fig. 15 is a schematic end view of a metal body according to Fig. 14;

[0054] Fig. 16 is a schematic detailed view according to detail B of a section of the surface structuring from Figure 14;

[0055] Fig. 17 is a schematic representation of a rod-shaped metal body having a surface structuring on one end face and one lateral surface, according to an embodiment;

[0056] Fig. 18 to 21 are schematic views of respective end faces of rod-shaped metal bodies provided with a front-side surface structuring according to different embodiments;

[0057] Fig. 22 is a schematic representation of a rod-shaped metal body having a surface structuring exclusively on the front side, according to an embodiment;

[0058] Fig. 23 is a schematic representation of a rod-shaped metal body having a surface structuring on one end face, according to an embodiment;

[0059] Fig. 24 is a partially schematic sectional view of a rod-shaped metal body, wherein the sectional plane of the sectional view runs transversely to the longitudinal axis of a rod-shaped metal body, according to an embodiment;

[0060] Fig. 25 is a schematic representation of an elevation of the surface structuring of a rod-shaped metal body according to an embodiment.

[0061] The figures describe a method and a component 1 that is manufactured as a product from the method described herein. The method serves to manufacture a component 1 that comprises a functional device 2 and a rod-shaped metallic body 3, wherein a rod-shaped metallic body 3 is provided 100 in one method step. Elevations and / or depressions are introduced into this rod-shaped body 3 to form a surface structure 4 on a surface section 5 of the rod-shaped body 3 (introduction 101).Also, a provision 102 of a functional device 2 and an overmolding 103 of the surface section 5 of the rod-shaped body 3 by means of a plastic material to form a connecting body 6 take place, wherein the overmolding 103 of the surface section 5 of the rod-shaped body 3 creates a connection between the rod-shaped body 3 and the functional device 2.

[0062] Before the surface section 5 of the rod-shaped body 3 is overmolded 103 to form the connecting body 6, a holding body 8 can be overmolded onto at least one functional element 7, 7' of the functional device 2 by at least partial overmolding 104 with a plastic material. Alternatively or additionally, at least one functional element 7, 7' of the functional device 2 can be designed as a magnetic active element, and during the at least partial overmolding 104 of the magnetic active element to form a holding body 8, an iron core 9 consisting of at least two iron elements can be at least partially overmolded. The component 1 created therefrom can be used, for example, as the rotor of an electrical machine.

[0063] As shown by way of example in Figure 11, at least one functional element 7, 7' of the functional device 2 can be designed as an electrical coil 40 or comprise such a coil. In this case, the rod-shaped body 3 connected (i.e. overmolded) to the functional device 7, 7' designed as an electrical coil 40 or comprising an electrical coil 40 can be used as an axle for supporting a rotor body 39 of an electrical machine. The surface structuring 4 can thus be used as a means for forming a connection between a stator body 41 comprising an electrical coil 40 and the rod-shaped body 3. The rotor body 39, which is provided in particular with a bearing section 38, can be inserted into a receiving space of the stator body 41 and threaded onto or mounted on the rod-shaped body 3 acting as an axle, see Figure 11. The bearing section 38 can, for example, be designed as a bearing sleeve.

[0064] According to the embodiment shown in Figure 13, at least one functional element 7, 7' can be designed as a coil 40 and can additionally be operatively connected to a further functional element of the component 1, in particular to a magnetic flux-carrying element of the component 1. For example, the further functional element can form a housing section which at least partially surrounds the functional element 7, 7' designed in particular as a coil 40. The further functional element, in particular the functional element 7, 7' serving as a housing for a coil 40, is preferably made of metal. In particular, the further functional element can be disk-like or disc-shaped.A further functional element that touches the functional element embodied as coil 40 or is arranged in its immediate vicinity within component 1 can be designed as a magnetically active element, so that during the intended operation of coil 40, the further functional element has a conductive or guiding and / or modifying property for an existing magnetic field. The further functional element can be formed, for example, by an iron core 9 described below.

[0065] The at least one functional element 7, 7' of the functional device 2, in particular all functional elements 7, 7' of the rod-shaped metallic body 3 provided with a functional device 2, and the holding body 8 can, for example, be overmolded with plastic material to form the connecting body 6 in such a way that the connecting body 6 comes into contact with the holding body 8 and the at least one functional element 7, 7'. Preferably, the connecting body 6 is in contact with the holding body 8 and with the at least one functional element 7, 7' and with the iron package 9. Thus, by injecting the plastic material to form the connecting body 6, an intimate connection can be created between the holding body 8, the at least one functional element 7, 7' and the iron package 9.

[0066] The introduction 101 of elevations and / or depressions for forming the surface structuring 4 into the rod-shaped body 3 can be carried out, for example, by means of at least one laser beam. Preferably, the surface structuring 4 is introduced at a location that does not correspond to the location where the plastic material is overmolded.

[0067] The surface structuring 4 can, for example, take the form of forming a plurality of partial surface sections 10, 10', 10", 11, 11', 11", wherein the partial surface sections 10, 10', 10", 11, 11', 11" have a rectilinear shape at least in sections, preferably predominantly, particularly preferably completely. The surface structuring 4 can alternatively or additionally take the form of forming a plurality of partial surface sections 10, 10', 10", 11, 11', 11", wherein the partial surface sections 10, 10', 10", 11, 11', 11" have a cross and / or star structure at least in sections, preferably predominantly, particularly preferably completely, see Figures 8 and 14.The surface structuring 4 can alternatively or additionally be designed such that a first group 12 of partial surface sections 10, 10', 10" and at least one further group of partial surface sections 11, 10, 11" are each arranged or formed in a row, in particular a straight row. For example, a first main extension line 20 of the first group of partial surface sections 10, 10', 10" can be aligned equidistantly from a further main extension line 21 of the further group 13 of partial surface sections 11, 11', 11". As shown, for example, in Figure 6, the partial surface sections 10, 10', 10" of a first group 12 can be arranged on a first, in particular straight, line (cf. main extension line 20) and a second group 13 of partial surface sections 11, 11', 11" can be arranged on a second, in particular straight, line (cf.Main extension line 21), wherein the two lines 20, 21 are aligned equidistant and / or parallel to one another. As shown in Figure 6, the partial surface sections 10, 10', 10" of the first group 12 and / or the partial surface sections 11, 11, 11" of the second group 12 can be designed in the manner of a wave or in the manner of a peak-valley structure. Preferably, at least individual partial surface sections 10, 10', 10", 11, 11, 11" are designed as a straight section, each leading from a valley point to a peak point or from a peak point to a valley point and thus forming a basic shape of a wave.The transition from a first partial area section 10 to an adjacent partial area section 10' can, for example, lead from a valley point of the first partial area section 10 to a valley point of the adjacent partial area section 10' or from a peak point of a partial area section 10' to a peak point of the adjacent partial area section 10". Overall, a waveform formed by spaced-apart partial area sections 10, 10', 10", 11, 11, 11" can thus be formed.

[0068] The surface structuring 4 can, for example, be carried out in such a way that at least one group 12, 13 of partial surface sections 10, 10', 10", 11, 11', 11", in particular at least two groups 12, 13 of partial surface sections 10, 10', 10", 11, 11', 11", are arranged helically and / or spirally over the circumference of the rod-shaped body 3. The partial surface sections 10, 10', 10", 11, 11', 11" can be arranged along the surface of a basic cylinder shape or a basic cone shape. The pitch of the helical or spiral shape can be constant over the longitudinal extent of the rod-shaped body 3 or can change in a constant manner or can be non-constant. For example, Figures 3, 8 and 14 show an arrangement of partial surface sections 10, 10', 10" which have a spiral or helical course over the circumference of the rod-shaped body 3.

[0069] As shown in Figure 5, the partial surface sections 10, 10', 10", 11, 11, 11" of a group 12, 13 of partial surface sections 10, 10', 10", 11, 11, 11" can be formed within an angular range a of a maximum of 350°, preferably a maximum of 280°, particularly preferably a maximum of 180°, most preferably a maximum of 90°, further preferably a maximum of 45°, furthermore preferably a maximum of 30°, viewed from the center of the rod-shaped body 3 in the cross-sectional representation. Because the angle a has a maximum of one of the stated values, in particular a value of a maximum of 45°, low disruptive influences, in particular low resistance, of the surface structuring 4 can be achieved in the case of plastic material introduction and movement within a gap 14, which is partially formed by the rod-shaped body 3, during the overmolding of the connecting body 6.In Figure 5, the circumferential extent of the partial surface sections 10, 10', 10" is within a small angular range a, which is, for example, less than 10°. In the embodiment shown in Figures 14 and 15, the angle a is 90°, ie the partial surface sections 10, 10', 10" which are assigned to a common group 12 are formed within the angular range formed by the angle a.

[0070] The angle ß indicates a center-to-center distance from a first main extension line 20 to an adjacent main extension line 21. In particular, the angular distance ß from adjacent main extension lines 20, 21 is at least 1.5 times, preferably 2.0 times, particularly preferably 2.5 times, and most preferably 3.0 times, the angle value α for the maximum spread of the partial surface sections 10, 10', 10" of an adjacent group 11, 12 of partial surface sections 10, 10', 10". With such a ratio of a and ß, it can be achieved that a sufficient gap 27 is present between the partial surface sections 10, 11 of adjacent groups 11, 12 in order to achieve a low resistance for a plastic material moving axially past the rod-shaped body 3 during the overmolding 103 of the surface structuring 4.

[0071] In the embodiment shown in Figures 14 and 15, the angular distance ß of adjacent main extension lines 20, 21 is equal to 90°, since four groups 11, 12 of partial surface sections 10, 10', 10", 11, 11', 11" are arranged at equal distances over the circumference of the rod-shaped body 3 and each main extension line 20, 21 extends over a quarter of the circumference.

[0072] As can be seen in Figure 14, the maximum transverse extent 42 of the rod-shaped body 3 in the region of or with the surface structuring 4 can correspond to at least 102%, preferably at least 105%, particularly preferably at least 106.5%, most preferably at least 107.5%, further preferably at least 110%, of the transverse extent 43 of the basic shape of the rod-shaped body 3 or of the rod-shaped body 3 without the surface structuring 4. Alternatively or additionally, the maximum transverse extent 42 of the rod-shaped body 3 in the region of or with the surface structuring 4 can correspond to a maximum of 140%, preferably a maximum of 125%, particularly preferably a maximum of 115%, further preferably a maximum of 110%, of the transverse extent 43 of the basic shape of the rod-shaped body 3 or of the rod-shaped body 3 without the surface structuring 4.The maximum transverse extent 42 of the rod-shaped body 3 in the region of the surface structuring 4 is formed by the maximum extent transverse to the longitudinal axis 15 of the rod-shaped body 3 and thereby formed by the elevations of the surface structuring 4. The transverse extent 43 of the basic shape of the rod-shaped body 4 is formed by the extent transverse to the longitudinal axis 15 of the rod-shaped body 3 in the region without surface structuring 4 and thus by the basic shape of the rod-shaped body. Thus, the transverse extent 43 of the basic shape of the rod-shaped body 4 can form an extent of the rod-shaped body 3 which is present there before a, in particular laser-assisted, creation of the surface structuring 4. In the case of a circular-cylindrical basic shape of a rod-shaped body 3 before the introduction of the surface structuring 4, the transverse extent 42 of its basic shape can correspond to the diameter of the circular cylinder.For example, the height of the surface structuring 4 can be greater than 0.10 mm, preferably more than 0.20 mm, particularly preferably more than 0.30 mm, most preferably more than 0.35 mm. Alternatively or additionally, the height of the surface structuring can be a maximum of 1.00 mm, preferably a maximum of 0.75 mm, particularly preferably a maximum of 0.50 mm, most preferably a maximum of 0.40 mm.

[0073] Figure 6 shows exemplary dimensions of the partial surface sections 10, 10', 10", 11, 1T, 11". For example, the surface structuring 4 can be designed as a plurality of partial surface sections 10, 10', 10", 11, 1T, 11", wherein the partial surface sections 10, 10', 10", 11, 1T, 11" have a rectilinear course at least in sections, preferably predominantly, particularly preferably completely. For example, at least one partial surface section 10, 10', 10", 11, 1T, 11", in particular all partial surface sections 10, 10', 10", 11, 1T, 11" of the rod-shaped body 3, can have a width 28 of 0.02 mm to 1.0 mm, preferably of 0.05 mm to 0.60 mm, particularly preferably of 0.10 mm to 0.40 mm, most preferably of 0.15 mm to 0.30 mm, further preferably of 0.20 mm.Alternatively or additionally, at least one partial surface section 10, 10', 10", 11, 1T, 11", in particular all partial surface sections 10, 10', 10", 11, 1T, 11" of the rod-shaped body 3, can have a length 29 of 0.25 mm to 2.0 mm, preferably of 0.35 mm to 1.4 mm, particularly preferably of 0.5 mm to 0.9 mm, most preferably 0.7 mm. An axial distance 30 between two adjacent partial surface sections 10, 10', 10", 11, 1T, 11" can be, for example, between 0.05 mm and 1.0 mm, preferably 0.1 mm to 0.6 mm, particularly preferably 0.2 mm to 0.45 mm, most preferably 0.3 mm.

[0074] Figure 16 shows partial surface sections 10, 10', 10", 11, 11T, 11" forming a cross. The cross shape used for the surface structuring 4 is formed from at least two, preferably from at least three, particularly preferably from four, subsections 44, 45, 46, 47. Each subsection 44, 45, 46, 47 is formed by a, in particular straight, line of a laser beam. The laser beam is preferably directed at the center 48 of the cross shape and moved outwards from this center 48. This means, for example, that the at least two, preferably at least three, particularly preferably all subsections 44, 45, 46, 47 for forming a cross shape of a partial surface section 10, 10', 10", 11, 11T, 11" are each formed by a laser beam moving outwards in the center 48 of the cross shape. This can result in a trench ora recess is formed in the surface of the rod-shaped body 3. In other words, at the exit point—see reference numeral 51—of the laser for forming the subsections 44, 45, 46, 47, a crater can form at the respective end of the subsection 44, 45, 46, 47. The craters or the ends 51 of the subsections 44, 45, 46, 47 can be formed at the end of the subsections 44, 45, 46, 47 opposite the center 48. Preferably, at least one subsection 44, 45, 46, 47, preferably all subsections 44, 45, 46, 47 of a cross, can have an elongated profile and a width in the range of 0.05 mm to 0.5 mm, preferably in the range of 0.07 mm to 0.40 mm, particularly preferably in the range of 0.9 mm to 0.20 mm. For example, at least one subsection 44 can form a 90° angle with at least one adjacent subsection 45 with respect to their main extension lines.

[0075] The maximum extension 50 of the subsections 44, 45, 46, 47 forming a cross shape can be, for example, between 0.10 mm to 5.0 mm, preferably 0.20 mm to 2.0 mm, particularly preferably 0.25 mm to 1.5 mm, further preferably 0.30 mm to 1.2 mm, most preferably 0.5 mm to 1.0 mm, further preferably 0.6 mm to 0.80 mm.

[0076] In particular, the stated values ​​of the width 28 and / or length 29 and / or the axial distance 30 apply to a rod-shaped body 3 with a cross-sectional extent of 4 mm to 20 mm, preferably 4.5 mm to 10 mm, particularly preferably 5.0 mm to 7.5 mm.

[0077] Before the overmolding 103 of the rod-shaped body 3 to form the connecting body 6, a gap 14 can be formed, for example, at least between the rod-shaped body 3 and the functional device 2, in particular at least between the rod-shaped body 3 and the holding body 8, wherein during the overmolding 103 of the rod-shaped body 3 to form the connecting body 6, the plastic material used for the overmolding is introduced into the gap 14 via at least two material strands along the longitudinal axis 15 of the rod-shaped body 3. The material strands represent the plastic material introduced into the gap 14 and spreading there. Preferably, the at least two material strands are introduced into the gap 14 in such a way that they move at least predominantly helically and / or spirally along the longitudinal axis 15.It can prove advantageous if the material strands spread out in an orientation and / or in a course around the longitudinal axis 15 of the rod-shaped body 3 that corresponds to or is similar to the partial surface sections 10, 10', 10", 11, 11', 11" of the surface structuring 4. The surface structuring 4 or its partial surface sections 10, 10', 10", 11, 11, 11" can thus have a dual function: on the one hand, it increases the strength of the connection between the rod-shaped body 3 and the connecting body 6, and on the other hand, it can have a plastic material guiding function during the encapsulation of the rod-shaped body. The plastic material guiding function is preferably carried out in such a way that the resistance for the introduced plastic material is as low as possible due to the partial surface sections 10, 10', 10", 11, 11, 11".

[0078] As shown by way of example in Figure 12, before or during the overmolding 103 of the rod-shaped body 3 for forming the connecting body 6, a gap 14 can be formed at least between the rod-shaped body 3 and the functional device 2, wherein the plastic material used for the overmolding 103 is introduced into the gap 14 from a starting point arranged at a first region 16, in particular end region, of the surface section 5 of the rod-shaped body 3 provided with the surface structuring 4 and moves within the gap 14 along a longitudinal extent of the surface section 5 of the rod-shaped body 3 to a second region 17, in particular end region, of the rod-shaped body 3, wherein the elevations and / or depressions of the surface structuring 4 are formed at a first region 16, in particular end region,of the surface section 5 facing the longitudinal section 18 of the surface section 5 have a stronger pronounced than the elevations and / or depressions of the surface structuring 4 of a second region 17, in particular end region,facing longitudinal section 19 of the surface section 5. In other words, within the gap 14 along the longitudinal extent of the rod-shaped body 3 or along the longitudinal extent of the surface structuring 4 of the rod-shaped body 3, the plasticized plastic material is moved from a starting point 35 (e.g. first region 16) to an end point 36 (e.g. second region 17). A resulting pressure drop of the plastic material with progressive penetration into the gap can be achieved by reducing the shape of the elevations and / or depressions of the surface structuring 4 in the flow direction 37. Such a pressure profile of the plastic material is shown by way of example in the lower half of Figure 12. Also, in the embodiment shown in Figure 12, the partial surface sections 10, 10', 11,1 T of the surface structuring 4 is larger or more pronounced than at the end point 36.,

[0079] An advantageous method can comprise inserting 105 at least one functional element 7, 7' of a functional device 2, in particular inserting at least one iron package 9, into a first tool part mold and forming 106 a cavity 31 by attaching at least one second tool part mold to the at least one first tool part mold and overmolding 104 the functional element 7, 7', in particular and additionally the iron package 9, by filling the cavity 31 with a plastic material to form the holding body 8. Furthermore, moving 107 the at least one second tool part mold to expose 32 a receiving space delimited by the holding body 8 and inserting 108 the rod-shaped body 3 into the receiving space, so that a rod-shaped body 3 received 33 in the receiving space is present.The first tool part mold is then closed 109 by the second tool part mold or by at least one third tool part mold to form a second cavity 34 adjacent at least to the rod-shaped body 3 and the holding body 8, and the rod-shaped body 3 is at least partially overmolded 103 by filling the second cavity with a plastic material to form the connecting body 6.

[0080] The plastic material of the connecting body 6 and / or the plastic material of the holding body 8 can, for example, be formed at least in sections, in particular completely, from a thermoplastic plastic or from a thermosetting plastic.

[0081] The component 1 produced in the method described herein can, for example, comprise at least one functional element 7, 7' of the functional device 2, which is designed as a magnetic active element, i.e., a functional element ?, 7' can have permanent magnetic properties or magnetizable properties or properties that at least temporarily generate a magnetic field. For example, the magnetic active element is designed as an energizable electrical coil, in particular made of copper wire. The rod-shaped body 3 can, for example, be used as the shaft of a rotor of an electrical machine (not shown), e.g. (a1) a DC motor or (a2) an AC and three-phase motor and / or (b1) a rotating field and traveling field machine or (b2) a commutator machine.In particular, the electrical machine in which the component 1 produced by the method described herein is used as a rotor can be a (three-phase) asynchronous machine or a (three-phase) synchronous machine of a permanent or separately excited type.

[0082] Alternatively or additionally, at least one functional element 7, 7' of component 1 can be designed as a body forming a, in particular closed, ring. In particular, at least one functional element 7, 7' can be designed as a bearing sleeve and / or as a bearing ring and / or as a contact element 25 forming a valve plate section, or as a component of the aforementioned elements. By way of example, Figure 7 shows a component 1 designed as a valve 22, wherein a valve stem 23 of the valve 22 is formed at least in sections, preferably predominantly, particularly preferably completely, from the rod-shaped metallic body 3 and a valve plate 24 of the valve 22 is formed at least in sections, preferably predominantly, from the connecting body 6. The at least one functional element 7, 7' can be designed as at least one contact element 25 of the valve 22, which, during intended operation, serves as a contact section of the valve 22 to a valve seat ring 26.The contact element 25 can be designed as a ring-shaped or sleeve-shaped body.

[0083] It is possible for the surface structuring 4 to be formed, in particular exclusively, on an end face 52 of the rod-shaped metallic body 3, see Figure 22. This makes it possible for an overmolding, i.e. the connecting body 6, to form an extension of the rod-shaped body 3 at the end of the rod-shaped body 3. Optionally, an outer surface of the rod-shaped body 3 can be flush with the connecting body 6 adjoining the end face of the rod-shaped body 3. The surface of the rod-shaped body 3 and / or of the adjoining connecting body 6 can serve, for example, as a bearing surface for a body 3 mounted on this surface, e.g. a rotor.In other words, an extension of the metallic rod-shaped body 3 by the frontal injection molding of the connecting body 6 made of plastic can serve as an axial fixing and / or limiting element for an element, e.g. a rotor, which is movably mounted on the rod-shaped body 3 used as an axis.

[0084] Alternatively, the surface structuring 4 can be formed, for example, on the end face 52 and additionally on a lateral surface 53 of the rod-shaped metallic body 3, see Figure 17. A fixing of the connecting body 6 to the rod-shaped body 3 exclusively on the lateral surface 53 is shown, for example, in Figure 1.

[0085] For example, the surface structuring 4 can be formed as at least one continuous or interrupted line, in particular a straight line. For example, the surface structuring 4 is formed as radially extending dashed or dotted lines, in particular dashed or dotted straight lines, see Figure 18. Alternatively or additionally, star-shaped and / or cross-shaped partial sections of the surface structuring 4 can be formed on the end face 52. The star-shaped and / or cross-shaped partial sections can, for example, lie on a circular line running concentrically to a center, see Figure 19. According to the optional embodiment shown in Figure 20, an annular section of the end face 52 can be provided with the surface structuring 4 or a central region 61 can be left out of the surface structuring 4.For example, as shown in Figure 21, the surface structuring 4 can be formed as circular sectors, in particular as a circular ring sector.

[0086] It is possible for a base body 54, which is movably mounted on, in particular in or on, the rod-shaped body 3, to be connected to a connecting section 53 of the connecting body 6 via a counter-connecting section 55 on the base body side in such a way that the base body 54, due to the interaction of the connecting section 53 and the counter-connecting section 55, has at least limited mobility (this may also include no mobility) in at least one direction, in particular in two directions, axial to the rod-shaped body 3. Limited mobility can be provided, for example, if mobility in the axial direction is enabled by means of mechanical play, e.g. less than 10 mm, preferably less than 5 mm, particularly preferably less than 2 mm, particularly preferably less than 1.0 mm. Mobility between the base body 54 and the connecting body 6 in both axial directions is preferably limited or prevented.A limited mobility of the base body 54 relative to the rod-shaped body 6 can, for example, also include a complete prevention of mobility along the longitudinal axis of the rod-shaped body 3.

[0087] The base body 54 can preferably comprise a predetermined bending region 59, so that a section 57 having the counter-connecting section 55 can execute a bending movement 60, in particular an elastic one, relative to a support section 58 ensuring support to the rod-shaped body 3. For example, during the course of a joining of the base body 54 and the rod-shaped body 3 and / or of the base body 54 and the connecting section 53, in particular by means of an axial movement, a brief deflection of the section 57 relative to the support section 58 occurs. In other words, the connection formed from the connecting section 53 and the counter-connecting section 55 can form a snap connection or a positive connection.Preferably, the connection, formed from connecting section 53 and counter-connecting section 55, is designed such that, in particular exclusively, a rotational movement about the longitudinal axis of the rod-shaped body 3 can be carried out. For example, the base body 54 can form a rotor, in particular of an electric machine. Optionally, a bearing means 56 can be arranged between the rod-shaped body 3 and the base body 54. The bearing means 56 is preferably designed as a rolling bearing, e.g., a ball and / or roller bearing, or as a plain bearing.

[0088] Figure 24 shows a cross section into a rod-shaped body 3 provided with a surface structuring 4. In this case, at least one action region 67, preferably all action regions 67, which arise in the course of a laser-assisted introduction (101) of the at least one depression, (a) a depth 62 of at least 200 micrometers, preferably at least 600 micrometers, particularly preferably at least 800 micrometers, particularly preferably at least 1000 micrometers, most preferably at least 1200 micrometers, and / or (b) a depth 62 in the range from 50 micrometers to 5000 micrometers, preferably 100 micrometers to 4000 micrometers, particularly preferably 200 micrometers to 3500 micrometers, further preferably 300 micrometers to 2500 micrometers, and / or (c) a depth 62 of at most 5000 micrometers, preferably 4000 micrometers, particularly preferably 3500 micrometers, further preferably 3000 micrometers, most preferably 2500 micrometers.The impact area is understood to be an area of ​​the rod-shaped body that forms, particularly adjacent to a depression, due to the laser-assisted formation of the depressions. In other words, the laser beam causes a change in the structure and / or density of the rod-shaped body 3. The laser acting on the rod-shaped body 3 leads to an area-dependent change in the structure and / or density of the rod-shaped body 3, thus forming the impact area 67. The depth 62 is measured from a base surface of the rod-shaped body 3.Optionally, the elevations of the surface structuring 4 can have (a) a height 63 of at least 50 micrometers, preferably 100 micrometers, particularly preferably 200 micrometers, further preferably 250 micrometers, most preferably 300 micrometers, and / or (b) a height 63 in the range from 50 micrometers to 1500 micrometers, preferably 100 micrometers to 1250 micrometers, particularly preferably 200 micrometers to 1000 micrometers, further preferably 250 micrometers to 800 micrometers, most preferably from 300 micrometers to 600 micrometers, and / or (c) a height 63 of at most 1500 micrometers, preferably 1250 micrometers, particularly preferably 1000 micrometers, further preferably 800 micrometers, most preferably 600 micrometers. The height 63 can be viewed, for example, from a base surface of the rod-shaped body 3, see Figure 24.The aforementioned minimum values ​​and / or maximum values ​​and / or value ranges can apply in particular to a rod-shaped 3 body which has a diameter in the range from 4000 mm to 10000 mm, preferably 5000 mm to 8000 mm, particularly preferably 5000 mm to 7000 mm.

[0089] Alternatively or additionally, a height 63 of at least one elevation of the surface structuring 4 to a depth 62 of at least one impact region 67, in particular adjacent to the at least one elevation, which is formed as a change in density on the rod-shaped body (3) during laser-assisted introduction 101 of depressions, can have a ratio in the range from 0.05 to 0.75, preferably 0.075 to 0.60, particularly preferably 0.10 to 0.50, further preferably 0.125 to 0.4, most preferably 0.10 to 0.35. In a particularly advantageous embodiment, the ratio can be in the range from 0.20 to 0.35, in particular in the range from 0.25 to 0.30. For example, the aforementioned ratio applies to the majority of the impact regions of the surface structuring 4 assigned to the elevations and respective depressions, in particular to all of them.The specified ratios of depth 62 and height 63 of, in particular, adjacent, the effective areas of depressions and elevations achieve the redistribution of material for the formation of elevations on the base surface of the rod-shaped body 3 by means of a small and at the same time deep cross-sectional removal of material from the base body of the rod-shaped body 3. By bombarding the rod-shaped body 3 with a laser, it is possible to form conical or truncated cone-shaped recesses and / or porous structures on the rod-shaped body 3, and in the process, particularly deep-lying material from the rod-shaped body 3 is "transported out" and provided as elevations of the surface structuring 4, see Figure 24.

[0090] It is possible for at least one impact area 67, which forms as a region with a density change on the rod-shaped body 3 during laser-assisted introduction 101 of at least one recess, to have a depth 62 to width 64 ratio in the range from 2 to 15, preferably from 4 to 10, particularly preferably from 5 to 9. Preferably, the at least one impact area 67 has a basic shape of a cone or a truncated cone. The impact area can be understood as an area heat-treated during the laser exposure to form the surface structuring.

[0091] Alternatively or additionally, the depressions can have a depth 62 that has a ratio to a diameter 65 of the rod-shaped body 3 in the range of 0.05 to 0.34, preferably from 0.075 to 0.30, particularly preferably from 0.10 to 0.25, further preferably from 0.15 to 0.25, most preferably from 0.175 to 0.25. The aforementioned depth values ​​refer to the depth of a depression.

[0092] In an optional exemplary embodiment, at least one elevation of the surface structuring 4 has a height 63 which has a ratio to a diameter 65 of the rod-shaped body 3 in the range from 0.010 to 0.300, preferably 0.015 to 0.250, particularly preferably 0.020 to 0.170, further preferably 0.030 to 0.170, most preferably 0.035 to 0.140, further preferably 0.040 to 0.100.

[0093] In addition to the method, the invention also relates to a component 1 comprising a functional device 2 comprising at least one functional element 7, 7' and a rod-shaped body 3, and which was produced using the method described herein. Finally, the invention relates to a device for producing a component 1 comprising at least one functional device 2 comprising a functional element 7, 7' and a rod-shaped body 3, wherein the device carries out a method described herein for producing the component 1.

[0094] REFERENCE MARKS LIST

[0095] component

[0096] Functional device rod-shaped body surface structuring surface section of 3 connecting body, functional element of 2 holding body iron package 0, 10', 10“ partial surface section 1, 1 T, 11“ partial surface section 2 first group of 10, 10', 10“ 3 further group of 11, 1 T, 11“ 4 gap between 2 and 3 5 longitudinal axis of 3 6 first area of ​​5 7 second area of ​​5 8 first longitudinal section of 5 9 second longitudinal section of 5 0 main extension line of 12 1 main extension line of 13 2 valve 3 valve stem of 22 4 valve disk of 22 5 contact element of 22 6 valve seat ring 7 gap 8 width of 10 9 length of 10 0 distance between 10, 10' 1 first cavity 2 exposure of receiving space 3 3 recorded in recording room 4 second cavity starting point

[0097] Endpoint

[0098] Flow direction

[0099] Camp section of 39

[0100] rotor body electrical coil

[0101] Stator body

[0102] Maximum transverse extension of 3 with 4

[0103] Maximum transverse extension of 3 without 4

[0104] Subsection

[0105] Subsection

[0106] Subsection

[0107] Subsection

[0108] center

[0109] Width of 44, 45, 46, 47 maximum extension of the cross forming 44, 45, 46, 47

[0110] End of 44, 45, 46, 47

[0111] Front side of 3

[0112] Connecting section of 6

[0113] Basic body

[0114] Counterconnection section of 54

[0115] Storage resources

[0116] Section of 54

[0117] Support section of 54

[0118] Predetermined bending range of 54

[0119] Bending movement

[0120] Central area of ​​52

[0121] Depth of depression

[0122] Height of elevation

[0123] Width of recess of a depression

[0124] Diameter of 3

[0125] Surface area of ​​3

[0126] Influence area of ​​3

[0127] Providing 3 Inserting 4 Providing 2 Overmolding to form 6 Overmolding to form 8 Inserting 7, 7' Forming Moving Inserting 3

Claims

PATENTED SPELLINGS 1. A method for producing a component (1) comprising a rod-shaped metallic body (3), comprising the following method steps: - Providing (100) a rod-shaped metallic body (3); - introducing (101) elevations and / or depressions to form a surface structuring (4) on a surface section (5) of the rod-shaped body (3); - Overmolding (103) the surface section (5) of the rod-shaped body (3) by means of a plastic material to form a connecting body (6), wherein the overmolding (103) of the surface section (5) of the rod-shaped body (3) creates a connection between the rod-shaped body (3) and the connecting body (6).

2. Method according to claim 1, characterized in that the method comprises providing (102) a functional device (2), wherein a connection between the rod-shaped body (3) and the functional device (2) is produced by the overmolding (103) of the surface section (5) of the rod-shaped body (3).

3. Method according to claim 2, characterized in that a functional device (2) is used which comprises at least one functional element (7, 7') which is designed as a magnetic active element, preferably at least one functional element (7, 7') designed as a magnetic active element is used which is designed as a magnet or as a magnetizable element or as an element influencing a magnetic field.

4. Method according to claim 3, characterized in that the component (1) is used as a component of an electrical machine, in particular the component is used as a stator or as a rotor or as a magnetic coil of an electrical machine.

5. Method according to one of claims 2 to 4, characterized in that before the overmolding (103) of the surface section (5) of the rod-shaped body (3) to form the connecting body (6), a holding body (8) is fastened to at least one functional element (7, 7') of the functional device (2) in the course of a joining process, in particular a holding body (8) is injection-molded by at least partial overmolding (104) with a plastic material.

6. Method according to one of claims 2 to 5, characterized in that at least one functional element (7, 7') of the functional device (2) is designed as a magnetic active element and in the course of the joining process for fastening a holding body (8) to the functional element (7, 7'), in particular in the course of the at least partial overmolding (104) of the magnetic active element to form a holding body (8), an iron package (9) consisting of at least two iron elements is at least partially overmolding.

7. The method according to claim 5 or 6, characterized in that the at least one functional element (7, 7'), in particular all functional elements (7, 7') of the rod-shaped metallic body (3) provided with a functional device (2), and the holding body (8) are overmolded with plastic material to form the connecting body (6) in such a way that the connecting body (6) is in contact with the holding body (8) and the at least one functional element (7, 7'), preferably the connecting body (6) is in contact with the holding body (8) and the at least one functional element (7, 7') and the iron package (9).

8. Method according to one of the preceding claims, characterized in that the introduction (101) of elevations and / or depressions for forming the surface structuring (4) into the rod-shaped body (3) is carried out by means of at least one laser beam.

9. Method according to one of the preceding claims, characterized in that the surface structuring (4) takes the form of a formation of a plurality of partial surface sections (10, 10', 10", 11, 1 T, 11"), wherein the partial surface sections (10, 10', 10", 11, 1 T, 11") have a rectilinear course at least in sections, preferably predominantly, particularly preferably completely.

10. Method according to one of the preceding claims, characterized in that the surface structuring (4) takes the form of a formation of a plurality of partial surface sections (10, 10', 10", 11, 1 T, 11"), wherein the partial surface sections (10, 10', 10", 11, 1 T, 11") at least in sections, preferably predominantly, particularly preferably completely, have a cross and / or star structure, in particular when viewed from above.

11. The method according to claim 9 or 10, characterized in that the surface structuring (4) is carried out in such a way that a first group (12) of partial surface sections (10, 10', 10", 11, 11', 11") and at least one further group of partial surface sections (10, 10', 10", 11, 11', 11") are each formed in a row, in particular a straight row, preferably a first longitudinal extension line of the first group of partial surface sections (10, 10', 10", 11, 11', 11") is aligned equidistant from one another to a further longitudinal extension line of the further group (13) of partial surface sections (10, 10', 10", 11, 11', 11").

12. Method according to one of claims 9 to 11, characterized in that the surface structuring (4) is carried out in such a way that at least one group of partial surface sections (10, 10', 10", 11, 11', 11"), in particular at least two groups of partial surface sections (10, 10', 10", 11, 11', 11"), are arranged helically and / or spirally over the circumference of the rod-shaped body (3).

13. Method according to one of claims 2 to 12, characterized in that before the overmolding (103) of the rod-shaped body (3) to form the connecting body (6), a gap (14) is formed at least between the rod-shaped body (3) and the functional device (2), in particular at least between the rod-shaped body (3) and the holding body (8), wherein during the overmolding (103) of the rod-shaped body (3) to form the connecting body (6), the plastic material used for the overmolding is introduced into the gap (14) via at least one material strand along the longitudinal axis (15) of the rod-shaped body (3), preferably the at least one material strand is introduced and / or guided into the gap (14) in such a way that it moves at least predominantly helically and / or spirally along the longitudinal axis (15).

14. Method according to one of claims 2 to 13, characterized in that before or during the overmolding (103) of the rod-shaped body (3) to form the connecting body (6), a gap (14) is formed at least between the rod-shaped body (3) and the functional device (2), wherein the plastic material used for the overmolding (103) is introduced into the gap (14) from a starting point arranged in a first region (16), in particular end region, of the surface section (5) of the rod-shaped body (3) provided with the surface structuring (4) and extends within the gap (14) along a longitudinal extent of the rod-shaped body (3) to a second region (17), in particular end region, of the surface section (5) of the rod-shaped body (3) provided with the surface structuring (4), wherein the elevations and / or depressions of the surface structuring (4) on a longitudinal section (18) of the rod-shaped body (3) facing the first region (16) have a stronger pronounced shape than the elevations and / or depressions of the surface structuring (4) region (16) of a longitudinal section (19) of the rod-shaped body (3) facing the second region (17).

15. Method according to one of claims 2 to 14, characterized by - inserting (105) at least one functional element (7, 7') of a functional device (2), in particular and inserting at least one iron package (9), onto a first tool part mold; - forming (106) a cavity by attaching at least one second tool part mold to the at least one first tool part mold and overmolding (104) the functional element (7, 7'), in particular and additionally the iron package (9), by filling the cavity with a plastic material to form the holding body (8); - moving (107) the at least one second tool part mold to expose a receiving space delimited by the holding body (8); - inserting (108) the rod-shaped body (3) into the receiving space; - closing (109) the first tool part mold by the second tool part mold or by at least one third tool part mold to form a second cavity adjacent at least to the rod-shaped body (3) and the holding body (8) and at least partially encapsulating (103) the rod-shaped body (3) by filling the second cavity with a plastic material to form the connecting body (6).

16. Method according to one of the preceding claims, characterized in that the plastic material of the connecting body (6) and / or the plastic material of the holding body (8) is formed at least in sections, in particular completely, from a thermoplastic plastic or from a thermosetting plastic.

17. Method according to one of the preceding claims, characterized in that the rod-shaped body (3) - as a shaft of a rotor of an electrical machine or - as a bearing element of a stator for supporting a rotor of an electrical machine is used.

18. Method according to one of claims 2 to 17, characterized in that an electrical coil is used as at least one functional element (7, 7') of the functional device (2).

19. Method according to one of claims 2 to 18, characterized in that a body forming a, in particular closed, ring is used as at least one functional element (7, 7'), in particular a bearing sleeve and / or a bearing ring and / or a contact element forming a valve disk section is used as the functional element (7, 7').

20. Method according to one of the preceding claims, characterized in that the surface structuring (4) is formed, in particular exclusively, on an end face (52) of the rod-shaped metallic body (3). 21 . Method according to one of the preceding claims, characterized in that a base body (54) which is movably mounted on, in particular in or on, the rod-shaped body (3) is connected to a connecting section (53) of the connecting body (6) via its counter-connecting section (55) in such a way that the base body (54) has at least a limited mobility in at least one direction, in particular in two directions, axially to the rod-shaped body (3) due to the interaction of the connecting section (53) and the counter-connecting section (55).

22. Method according to one of the preceding claims, characterized in that an impact area (67) exhibiting a density change in the course of a laser-assisted introduction (101) of at least one depression is formed or can be formed on the rod-shaped body (3), wherein the impact area (67) - a depth (62) of at least 200 micrometers, preferably at least 600 micrometers, particularly preferably at least 800 micrometers, particularly preferably at least 1000 micrometers, most preferably at least 1200 micrometers, and / or - a depth (62) in the range of 50 micrometers to 5000 micrometers, preferably 100 micrometers to 4000 micrometers, particularly preferably 200 micrometers to 3500 micrometers, further preferably 300 micrometers to 2500 micrometers, and / or - a depth (62) of maximum 5000 micrometers, preferably 4000 micrometers, especially preferably 3500 micrometers, more preferably 3000 micrometers, most preferably 2500 micrometers.

23. Method according to one of the preceding claims, characterized in that the elevations of the surface structuring (4) - a height (63) of at least 50 micrometers, preferably 100 micrometers, particularly preferably 200 micrometers, further preferably 250 micrometers, most preferably 300 micrometers, and / or - a height (63) in the range from 50 micrometers to 1500 micrometers, preferably from 100 micrometers to 1250 micrometers, particularly preferably from 200 micrometers to 1000 micrometers, further preferably from 250 micrometers to 800 micrometers, most preferably from 300 micrometers to 600 micrometers, and / or - have a height (63) of at most 1500 micrometers, preferably 1250 micrometers, particularly preferably 1000 micrometers, further preferably 800 micrometers, most preferably 600 micrometers.

24. Method according to one of the preceding claims, characterized in that a height (63) of at least one elevation of the surface structuring (4) to a depth (62) of at least one area of ​​action (67), in particular adjacent to the elevation, which area of ​​action forms as a change in density on the rod-shaped body (3) in the course of a laser-assisted introduction (101) of depressions, has a ratio in the range from 0.05 to 0.75, preferably 0.075 to 0.60, particularly preferably 0.10 to 0.50, further preferably 0.125 to 0.4, most preferably 0.10 to 0.

35.

25. Method according to one of the preceding claims, characterized in that at least one action region (67), which is formed as a region with a density change on the rod-shaped body (3) during a laser-assisted introduction (101) of at least one depression, has a depth (62) to width (64) ratio in the range from 2 to 15, preferably from 4 to 10, particularly preferably from 5 to 9, preferably the at least one action region (67) has a basic shape of a cone or a truncated cone. The 26. Method according to one of the preceding claims, characterized in that impact areas (67) which arise during a laser-assisted introduction (101) of Depressions form regions with a density change on the rod-shaped body, having a depth (62) which has a ratio to a diameter (65) of the rod-shaped body (3) in the range from 0.05 to 0.34, preferably from 0.075 to 0.30, particularly preferably from 0.10 to 0.25, further preferably from 0.15 to 0.25, most preferably from 0.175 to 0.

25.

27. Method according to one of the preceding claims, characterized in that at least one elevation of the surface structuring (4) has a height (63) which has a ratio to a diameter (65) of the rod-shaped body (3) in the range from 0.010 to 0.300, preferably 0.015 to 0.250, particularly preferably 0.020 to 0.170, further preferably 0.030 to 0.170, most preferably 0.035 to 0.140, further preferably 0.040 to 0.

100.

28. Component (1) having a rod-shaped body (3), produced by a method according to one of the preceding claims.

29. Device for producing a component (1) having at least one rod-shaped body (3) by means of a method according to one of claims 1 to 27.

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