DE102023120418A1 - Method for producing a structural element composite and structural element composite - Google Patents

Abstract

Structural element composite, e.g. plastic component, wherein the structural element composite can preferably be flat and/or plate-shaped and/or grid-shaped, wherein the structural element composite comprises the following: a support structure element, which can e.g. be a plastic support structure element, wherein the support structure element can preferably be flat and/or plate-shaped and/or grid-shaped, and an adaptation element fixed to the support structure element, which can e.g. be a plastic adaptation element, wherein the support structure element and the adaptation element are connected to one another in a form-fitting, force-fitting and/or material-fitting manner.

Description

The present invention relates to a structural element assembly. The structural element assembly can be particularly suitable for the production of devices and the handling of arrangements which have a large number of regularly positioned functional elements.

An example of a device having a plurality of regularly positioned functional elements is a lighting device. It can have a plurality of regularly positioned functional elements in the form of light sources, e.g. LEDs.

An example of an arrangement that has a large number of regularly positioned functional elements is a vessel arrangement. It can have a large number of regularly arranged functional elements in the form of vessels.

An example of an arrangement that has a large number of regularly positioned functional elements is a charging device. It can have a large number of regularly arranged functional elements in the form of vessels or holders for vessels or structural profiles. A substrate can be arranged in each of the vessels and the respective substrate can be exposed to a treatment medium under precisely controllable conditions. For this purpose, it can be provided that the charging device has, in addition to zones for positioning or holding vessels, openings that are exactly spaced apart from one another and from these zones, which extend from a top to a bottom of the charging device and through which a treatment fluid can be passed from bottom to top or from top to bottom through the charging device. This can ensure that the substrates in the vessels are each exposed to almost exactly the same treatment conditions and that a homogeneous treatment result is achieved, i.e. the substrate arranged in one of the vessels is changed in the same way after treatment with the treatment medium as another substrate arranged in another vessel. The substrates arranged in the vessels can be, for example, medical preparations or compositions for producing medical preparations. Alternatively, the substrates can be precision products, e.g. spectacle lenses, contact lenses or plastic covers for displays or plastic precursors for the manufacture of precision products. For the quality of the preparations and precision products obtained, it can be crucial that the intended treatment conditions for each substrate in each of the vessels are precisely adhered to within narrow tolerance ranges, as otherwise, for example, the desired conversion levels cannot be achieved or surface coatings on the substrates cannot be reliably provided in the desired form.

The present invention is based on the object of providing an efficiently usable structural element composite in the simplest possible manner.

This object is achieved according to the invention by a structural element composite according to the relevant independent claim.

The structural element composite can in particular be a plastic component.

The term “in particular” is used in this description and the appended claims to describe possible facultative and/or optional features.

The structural element composite can preferably be flat.

The structural element composite can preferably be plate-shaped.

The structural element composite can preferably be lattice-shaped.

The structural element composite can, for example, be flat and plate-shaped.

The structural element composite can, for example, be flat and lattice-shaped.

The structural element composite comprises a supporting structural element.

The supporting structure element can in particular be a plastic supporting structure element.

The plastic support structure element can preferably be a reinforced plastic support structure element, e.g. a fiber-reinforced plastic support structure element.

The fiber-reinforced plastic support structure element can preferably be a glass fiber-reinforced plastic support structure element. It can preferably contain 10 wt.% to 90 wt.%, particularly preferably 20 wt.% to 75 wt.%, very particularly preferably 30 wt.% to 70 wt.%, e.g. 25 wt.% to 55 wt.%, glass fibers.

The plastic of the plastic support structure element, preferably the fiber-reinforced plastic support structure element, can preferably contain or be made from:
polycarbonate (PC)
acrylonitrile-butadiene-styrene copolymer (ABS)
polyamide (PA)
polypropylene (PP)
polybutylene terephthalate (PBT)

The supporting structure element may preferably be flat.

The supporting structure element can preferably be plate-shaped.

The supporting structure element can preferably be lattice-shaped.

The supporting structure element can, for example, be flat and plate-shaped.

The supporting structure element can, for example, be flat and lattice-shaped.

The structural element assembly includes an adaptation element fixed to the supporting structure element.

The adjustment element can, for example, be a plastic adjustment element.

The supporting structure element and the adaptation element are connected to each other in a form-fitting, force-fitting and/or material-fitting manner.

This may mean in particular that a connection between the supporting structure element and the adaptation element is characterized by at least one of the following three properties: positive locking, frictional locking and material locking.

The adaptation element can in particular be a structural element that is different from the supporting structure element. The structural element assembly can therefore in particular comprise structural elements that are connected to one another, including a supporting structure element and an adaptation element.

The supporting structure element is called a supporting structure element because it has a structure that supports the adaptation element.

The adaptation element is referred to as an adaptation element because the supporting structure element, where the adaptation element is fixed to the supporting structure element, is adapted or adaptable to a specific use by an appropriate choice and design of the adaptation element, for example to rest on LEDs or other light sources during the manufacture of a lighting device or to position vessels thereon in a targeted manner.

If the supporting structure element and the adaptation element are connected to one another in a form-fitting manner, the form-fitting connection of the supporting structure element and adaptation element can have an undercut. The undercut can preferably make it more difficult to separate the adaptation element from the supporting structure element and/or prevent the adaptation element from being separated from the supporting structure element without causing damage.

It can be advantageous if the positive connection comprises a section of the support structure element that extends between sections of the adaptation element. The section of the support structure element can extend in particular between a section of the adaptation element arranged on one side of the support structure element and a section of the adaptation element arranged on the other side of the support structure element.

It may be advantageous if the adjustment element has an adjustment section.

The adjustment section can, for example, be a foamed section.

It can be advantageous if the adaptation element is a plastic adaptation element and the plastic adaptation element has the adaptation section. The foamed section is then in particular a foamed plastic section.

It can be advantageous if the adaptation element has an overhang zone in which the adaptation element projects beyond the supporting structure element.

Preferably, the support structure element can have an adaptation side and a rear side opposite the adaptation side.

In the overhang zone, the adaptation element can preferably protrude beyond the adaptation side of the supporting structure element.

It may be preferred if at least part of the adaptation section lies in the overhang zone.

It may be preferred if the entire adjustment section lies in the overhang zone or if a part of the adjustment section lies in the overhang zone and another part of the adjustment section does not lie in the overhang zone.

It can be advantageous if the adaptation element has a compact section. Preferably, the adaptation element may be the plastic adaptation element and the compact portion may be a compact plastic portion.

It can be advantageous if the adjustment element has a connection zone.

The connection between the supporting structure element and the adaptation element can, for example, be a connection mediated by the connection zone of the adaptation element.

It may be preferred if at least part of the compact section lies in the connection zone.

It may be preferred if the entire compact section lies in the connection zone or a part of the compact section lies in the connection zone and another part of the compact section lies outside the connection zone.

It can be advantageous if the density of the supporting structure element is greater than the average density of the adaptation element.

The density of the support structure element can be essentially the same across the entire support structure element. This can mean in particular that the density of the support structure element only varies within small limits of, for example, 15%. It can be advantageous if the support structure element is a plastic support structure element that does not have a foamed section.

The density of the adaptation element in the adaptation section, for example the foamed section, can differ significantly from the density of the adaptation element in the compact section. Therefore, reference is made to the average density of the adaptation element. This can be determined from the volume and the density of the adaptation element.

It is preferred if the density of the support structure element is at least 150%, preferably at least 175%, particularly preferably at least 230%, very preferably 270%, e.g. at least 350%, of an average density of the adaptation element.

The average density of the adaptation element can in particular be at most 0.9 g/cm ³ , preferably at most 0.75 g/cm ³ , particularly preferably at most 0.65 g/cm ³ , e.g. at most 0.55 g/cm ³ . It can be advantageous if the average density of the adaptation element is at least 0.05 g/cm ³ .

In the adaptation section, which may be, for example, a foamed section, the density of the adaptation element may be lower than the average density of the adaptation element.

The density of the adaptation section can in particular be at most 0.7 g/cm ³ , preferably at most 0.6 g/cm ³ , particularly preferably at most 0.55 g/cm ³ , e.g. at most 0.5 g/cm ³ . It can be advantageous if the density of the adaptation section is at least 0.02 g/cm ³ . The density of the adaptation section can be determined by cutting it out of the adaptation element and then determining the volume and mass of the cut-out adaptation section and calculating the density of the adaptation section from this.

In the event that the density of the supporting structure element is not the same across the entire supporting structure element and the supporting structure element has, for example, a foamed supporting structure element section, the average density of the supporting structure element is taken into account as the density of the supporting structure element.

It may be advantageous if an adaptation surface of the adaptation element is softer than a supporting structure surface of the supporting structure element.

It can be advantageous if the adaptation element is softer than the supporting structure element.

For example, an adaptation surface of the adaptation element may be softer than a support structure surface of the support structure element and/or the adaptation element may be softer than the support structure element.

The adaptation surface of the adaptation element may be the surface of the adaptation element that faces a viewer who looks at the adaptation element from the adaptation side orthogonal to an extension plane of the structural element composite.

The adaptation surface of the adaptation element may be one of a plurality of surfaces of the adaptation element facing a viewer looking at the adaptation element from the adaptation side orthogonal to an extension plane of the structural element composite.

The extension plane can in particular be a plane extending between the adaptation side and the rear side of the supporting structure element through the supporting structural element, e.g. a plane extending flatly between the adaptation side and the back of the supporting structure element through the supporting structure element. The extension plane is of course in particular a geometric auxiliary object to which reference is made for the definition of the invention.

The extension plane can extend in particular parallel to the adaptation side and to the rear side of the support structure element through the support structure element, wherein in particular any unevenness or surface structures of the support structure element can be disregarded.

In particular, the extension plane can extend through the supporting structure element in such a way that it would divide the supporting structure element into two supporting structure element halves of identical mass if the supporting structure element were cut in the extension plane.

Whether an adaptation surface of the adaptation element is softer than a supporting structure surface of the supporting structure element can be determined in particular according to DIN ISO 48-4:2021-02 The adaptation surface of the adaptation element can be considered softer than the supporting structure surface of the supporting structure element in particular if the penetration depth of the indenter according to Shore D into the adaptation surface is greater than into the supporting structure surface.

Preferably, the same test procedure can be used to determine whether the adaptation element is softer than the supporting structure element.

If the adaptation element has multiple adaptation surfaces, the softest of the adaptation surfaces may preferably be decisive for determining whether the adaptation surface is softer than the support structure surface.

Penetration depths are preferably measured orthogonally to the plane of extension. It can be advantageous if the penetration depth into the adaptation surface is at least 1.8 times as large as the penetration depth into the supporting structure surface, for example at least 2.6 times as large as the penetration depth into the supporting structure surface.

It can be particularly advantageous if the hardness of the adaptation surface of the adaptation element is 10 to 90 Shore A 10. This value can be determined in particular according to DIN ISO 48-4:2021-02 The 10 in the specification “Shore A 10” stands for a contact pressure duration of 10 seconds.

If the adjustment element has multiple adjustment surfaces, the specified value applies to the softest of the adjustment surfaces.

The indenter can be placed particularly in the middle of the respective adaptation surface.

Advantageously, a compression hardness of the adaptation element is at least approximately 2 kPa, preferably at least approximately 5 kPa, in particular at least approximately 10 kPa.

Alternatively or additionally, it can be provided that the compression hardness of the adaptation element is at most approximately 100 kPa, preferably at most approximately 80 kPa, for example at most approximately 50 kPa.

In one embodiment, the compression hardness may be, for example, approximately 25 kPa.

For example, to determine the compression hardness, the adaptation element is acted upon in such a way that it is compressed by 40% of its initial size, in particular at 20 °C.

Further details on the compression hardness are described in connection with the process.

In particular, but not only, relatively soft adaptation elements can be produced using the foamed sections, which were described above. These can in particular have soft adaptation surfaces, which were also described above. This has proven to be particularly advantageous, not least because they can compensate for remaining manufacturing-related unevenness of flat plate-shaped or flat grid-shaped supporting structure elements in typical uses of the structural element composite.

Particularly in the case of large-area plate-shaped or grid-shaped load-bearing structural elements, unevenness caused by production within certain tolerances is unavoidable. Without adjustment elements that can compensate for these unevennesses in whole or in part, many load-bearing structural elements would have to be declared as scrap and would not be available for intended use or further processing.

The invention can in particular contribute to reducing the waste of supporting structure elements in a production process. It can also help to ensure that even larger-area load-bearing structure elements, which inherently have greater unevenness, can be made available for certain uses in the first place. This is because these unevennesses can be efficiently compensated for over large areas by a correspondingly large number of adjustment elements.

This can also help to provide an efficiently usable structural element composite in the simplest possible way.

It can be particularly advantageous if the adaptation element is a first adaptation element and the structural element composite comprises a second adaptation element and optionally a third adaptation element.

The structural element composite may optionally comprise a fourth adjustment element, optionally a fifth adjustment element, optionally a sixth adjustment element, optionally a seventh adjustment element, optionally an eighth adjustment element, optionally a ninth adjustment element, and optionally a tenth adjustment element.

The number of adaptation elements that the structural element assembly comprises is not limited. It can be advantageous if the number of adaptation elements comprised by the structural element assembly is at most 50,000, preferably at most 15,000, particularly preferably at most 4,000, for example at most 1,000.

It can be particularly advantageous if the structural element composite comprises an adaptation element connection section.

The adjustment element connecting section connects the first adjustment element to the second adjustment element.

It may be preferable if the adjustment element connecting portion is connected to the first adjustment element, the second adjustment element and the third adjustment element.

It may be preferable if the adjustment element connecting portion is connected to the first adjustment element, the second adjustment element, the third adjustment element and the fourth adjustment element.

It may be preferable if the adjustment element connecting portion is connected to the first adjustment element, the second adjustment element, the third adjustment element, the fourth adjustment element and the fifth adjustment element.

It may be preferable if the adjustment element connecting portion is connected to the first adjustment element, the second adjustment element, the third adjustment element, the fourth adjustment element, the fifth adjustment element and the sixth adjustment element.

It may be preferable if the adjustment element connecting portion is connected to the first adjustment element, the second adjustment element, the third adjustment element, the fourth adjustment element, the fifth adjustment element, the sixth adjustment element and the seventh adjustment element.

It may be preferable that the adjustment element connecting portion is connected to the first adjustment element, the second adjustment element, the third adjustment element, the fourth adjustment element, the fifth adjustment element, the sixth adjustment element, the seventh adjustment element and the eighth adjustment element.

It may be preferable that the adjustment element connecting portion is connected to the first adjustment element, the second adjustment element, the third adjustment element, the fourth adjustment element, the fifth adjustment element, the sixth adjustment element, the seventh adjustment element, the eighth adjustment element and the ninth adjustment element.

It may be preferable that the adjustment element connecting portion is connected to the first adjustment element, the second adjustment element, the third adjustment element, the fourth adjustment element, the fifth adjustment element, the sixth adjustment element, the seventh adjustment element, the eighth adjustment element, the ninth adjustment element and the tenth adjustment element.

The adaptation element connecting section can connect the adaptation elements to which it is connected directly or indirectly.

If an adaptation element is indirectly connected to another adaptation element via the adaptation element connection section, this can mean, for example, that between these two, indirectly connected to each other via the adaptation element connection section connected adjustment elements there is another adjustment element.

The indirect connection can then exist via the intermediate adaptation element.

It can be particularly advantageous if the structural element composite comprises groups of adaptation elements, wherein the adaptation element belongs to a first group of adaptation elements.

Preferably, the first adaptation element and the second adaptation element may belong to the first group of adaptation elements.

For example, the first adjustment element, the second adjustment element and the third adjustment element may belong to the first group of adjustment elements.

It may be advantageous if the first group of adjustment elements also includes the fourth adjustment element, optionally also the fifth adjustment element, optionally also the sixth adjustment element, optionally also the seventh adjustment element, optionally also the eighth adjustment element, optionally also the ninth adjustment element and optionally also the tenth adjustment element.

Preferably, the adaptation element connecting section can be a first adaptation element group connecting section and the structural element assembly can comprise a second adaptation element group connecting section, wherein the second adaptation element group connecting section connects a first adaptation element of a second group of adaptation elements to a second adaptation element of the second group of adaptation elements.

It may be preferable if the second adjustment element group connecting portion is connected to the first adjustment element, the second adjustment element and the third adjustment element of the second group of adjustment elements.

It may be preferred if the second adjustment element group connecting portion is connected to the first, the second, the third and the fourth adjustment element of the second group of adjustment elements.

It may be preferred if the second adjustment element group connecting portion is connected to the first, the second, the third, the fourth and the fifth adjustment element of the second group of adjustment elements.

It may be preferred if the second adjustment element group connecting portion is connected to the first, the second, the third, the fourth, the fifth and the sixth adjustment element of the second group of adjustment elements.

It may be preferable if the second adjustment element group connecting portion is connected to the first, second, third, fourth, fifth, sixth and seventh adjustment elements of the second group of adjustment elements.

It may be preferable if the second adjustment element group connecting portion is connected to the first, the second, the third, the fourth, the fifth, the sixth, the seventh and the eighth adjustment element of the second group of adjustment elements.

It may be preferable if the second adjustment element group connecting portion is connected to the first, second, third, fourth, fifth, sixth, seventh, eighth and ninth adjustment elements of the second group of adjustment elements.

It may be preferable if the second adjustment element group connecting portion is connected to the first, the second, the third, the fourth, the fifth, the sixth, the seventh, the eighth, the ninth and the tenth adjustment elements of the second group of adjustment elements.

It can be advantageous if the structural element assembly comprises several, preferably at least three, particularly preferably at least five, very particularly preferably at least eight groups of at least three adaptation elements each connected to one another via adaptation element connecting sections.

It can be advantageous if the structural element assembly comprises several, preferably at least three, particularly preferably at least five, very particularly preferably at least eight groups of at least four adaptation elements each connected to one another via adaptation element connecting sections.

It can be advantageous if the structural element composite comprises several, preferably at least three, particularly preferably at least five, very particularly preferably at least eight groups of at least five adaptation elements each connected to one another via adaptation element connecting sections.

It can be advantageous if the structural element assembly comprises several, preferably at least three, particularly preferably at least five, very particularly preferably at least eight groups of at least six adaptation elements each connected to one another via adaptation element connecting sections.

It can be advantageous if the structural element assembly comprises several groups of at least seven adaptation elements each connected to one another via adaptation element connecting sections.

It can be advantageous if the structural element assembly comprises several groups of at least eight adaptation elements each connected to one another via adaptation element connecting sections.

It can be advantageous if the structural element assembly comprises several groups of at least nine adaptation elements each connected to one another via adaptation element connecting sections.

It can be advantageous if the structural element assembly comprises several groups of at least ten adaptation elements each connected to one another via adaptation element connecting sections.

It can be particularly advantageous if the first adaptation element, the second adaptation element and the adaptation element connecting section connecting the first adaptation element to the second adaptation element is a one-piece plastic element.

It can be particularly advantageous if the first adaptation element, the second adaptation element and the adaptation element connecting section connecting the first adaptation element to the second adaptation element are made of a continuous plastic material.

It may be preferred if at least one group of adaptation elements, including the adaptation element connecting section connecting the adaptation elements of this group, is a one-piece plastic element.

It may be preferred if at least one group of adaptation elements, including the adaptation element connecting section connecting the adaptation elements of this group, is made of a continuous plastic material.

For example, it may be preferred if the first group of adaptation elements, including the associated first adaptation element group connecting portion, is a first one-piece plastic element.

For example, it may be preferred if the first group of adaptation elements, including the associated first adaptation element group connecting portion, is made of a first continuous plastic material.

It may be preferred if the second group of adaptation elements, including the associated second adaptation element group connecting portion, is a second one-piece plastic element.

For example, it may be preferred if the second group of adjustment elements, including the associated second adjustment element group connecting portion, is made of a second continuous plastic material.

It may be preferred if the first group of adaptation elements, including the associated first adaptation element group connecting portion, is a first one-piece plastic element and/or is made from a first continuous plastic material, and the second group of adaptation elements, including the associated second adaptation element group connecting portion, is a second one-piece plastic element and/or is made from a second continuous plastic material.

A one-piece plastic element referred to herein, for example the one-piece plastic element and/or the first one-piece plastic element and/or the second one-piece plastic element, may contain a plastic material or consist of a plastic material.

The plastic material contains a polymer or a mixture of different polymers. The plastic material can preferably contain one or more additives. Additives are in particular reinforcing materials, fillers, flame retardants, colorants, heat stabilizers, light stabilizers, antioxidants, stabilizers, Plasticizers, blowing agents, lubricants, antistatic agents and impact modifiers.

It can be particularly advantageous if the plastic material contains at least one blowing agent. Foamed sections of the adaptation elements can be formed with the blowing agent.

It can be particularly advantageous if the plastic material contains at least one reinforcing material.

• - Glasfasern,
• - Carbonfasern,
• - Amidfasern, insbesondere Aramidfasern, und/oder
• - Polyacrylnitril-Fasern, insbesondere oxidierte Polyacrylnitril-Fasern.

The at least one reinforcing material may comprise fibres, e.g.

• - glass fibers,
• - carbon fibers,
• - amide fibres, in particular aramid fibres, and/or
• - Polyacrylonitrile fibres, in particular oxidised polyacrylonitrile fibres.

It can be advantageous if the fibers are dispersed in the polymer or in the mixture of different polymers.

It can be particularly advantageous if the plastic material is an elastomer material, e.g. a thermoplastic elastomer material.

It is known that thermoplastic elastomers are plastics that behave similarly to classic elastomers at room temperature, but can be plastically deformed when heat is applied and thus exhibit thermoplastic behavior.

When the plastic material is a thermoplastic elastomer material, it contains in particular a polymer selected from thermoplastic elastomers or a mixture of different polymers containing a thermoplastic elastomer.

In the case of thermoplastic elastomers, elastic polymer chains in particular can be incorporated into thermoplastic material. They can be processed in a purely physical process in a combination of high shear forces, heat exposure and subsequent cooling.

• - thermoplastische Polyamidelastomere,
• - thermoplastische Copolyesterelastomere,
• - thermoplastische Elastomere auf Olefinbasis, z. B. PP/EPDM,
• - thermoplastische Styrol-Blockcopolymere, z. B. SBS, SEBS, SEPS, SEEPS und MBS,
• - thermoplastische Elastomere auf Urethanbasis,
• - thermoplastische Vulkanisate oder vernetzte thermoplastische Elastomere auf Olefinbasis, z. B. PP/EPDM.

If the plastic material is a thermoplastic elastomer material, the plastic material may preferably contain at least one of the following thermoplastic elastomers:

• - thermoplastic polyamide elastomers,
• - thermoplastic copolyester elastomers,
• - olefin-based thermoplastic elastomers, e.g. PP/EPDM,
• - thermoplastic styrene block copolymers, e.g. SBS, SEBS, SEPS, SEEPS and MBS,
• - urethane-based thermoplastic elastomers,
• - thermoplastic vulcanizates or cross-linked olefin-based thermoplastic elastomers, e.g. PP/EPDM.

Thermoplastic polyamide elastomers are also abbreviated as TPA (also known as TPE-A).

Thermoplastic copolyester elastomers are also abbreviated as TPC (also known as TPE-E).

Olefin-based thermoplastic elastomers are also abbreviated as TPO (also known as TPE-O).

Thermoplastic styrene block copolymers are also abbreviated as TPS (also known as TPE-S).

Thermoplastic elastomers based on urethane are also abbreviated as TPU (also known as TPE-U).

Thermoplastic vulcanizates or cross-linked thermoplastic elastomers based on olefins are also abbreviated as TPV (also known as TPE-V).

Alternatively or additionally, the plastic material may comprise or be formed from expandable polyethylene, expandable polyvinyl, thermoplastic polyurethane or similar soft plastics.

When an adaptation element or a plastic adaptation element is mentioned herein, this may mean, for example, a thermoplastic elastomer adaptation element. This may apply in particular to each individual adaptation element mentioned herein of all groups of adaptation elements mentioned herein.

Each of the adaptation elements described herein may, independently of any other adaptation element described herein, have an adaptation portion, which may, for example, be a foamed portion.

Each of the adjustment elements described herein may, independently of any other adjustment element described herein, have a projection zone in which the adjustment element projects beyond the supporting structure element, wherein it may be preferred if at least a part of the adaptation section lies in the projection zone.

Each of the adaptation elements described herein may have a compact portion independent of any other adaptation element described herein.

Each of the adaptation elements described herein may have a connection zone independently of any other adaptation element described herein, wherein the connection between the support structure element and the adaptation element is a connection mediated by the connection zone of the adaptation element, wherein it may be preferred if at least part of the compact section lies in the connection zone.

The density of the support structure element may preferably be greater than the average density of each of the adaptation elements mentioned herein, independently of the average density of any other of the adaptation elements mentioned herein.

For each adaptation element mentioned herein, independently of any other adaptation element mentioned herein, the adaptation surface can be softer than the support structure surface of the support structure element and/or the respective adaptation element can be softer than the support structure element.

It can be particularly advantageous if the adjustment elements of several groups of adjustment elements are arranged regularly.

Preferably, the adaptation elements can be a plurality of groups of adaptation elements arranged regularly over the adaptation side of the flat and plate-shaped structural element composite or the flat and grid-shaped structural element composite.

A planar regular arrangement can in particular mean that the adjustment elements are each located on nodes of an auxiliary grid.

The auxiliary grid is a geometric auxiliary object that is used solely for the purpose of describing the regular planar arrangement. The grid structure of the auxiliary grid can be independent of a grid-shaped structure of the structural element composite. However, the invention does not of course exclude the possibility that the grid structure of the auxiliary grid is related to a grid-shaped structure of the structural element composite or that it completely or partially coincides with it.

The auxiliary grid can in particular be an imaginary auxiliary grid located on the adjustment side.

The auxiliary grid can preferably be an auxiliary grid constructed from straight lines intersecting at the nodes.

A first set of straight lines of the auxiliary grid can consist of at least three straight lines aligned parallel to one another and evenly spaced from one another. A second set of straight lines of the auxiliary grid can consist of at least three straight lines aligned parallel to one another and evenly spaced from one another.

These two sets of lines can define an auxiliary grid made up of quadrilaterals. The side lengths and angles of these quadrilaterals are all equal. The quadrilaterals can be parallelograms, rhombuses or squares.

It can be advantageous if the auxiliary grid is also defined by a third set of straight lines. The third set of straight lines of the auxiliary grid can consist of at least three straight lines that are aligned parallel to one another and evenly spaced from one another. The auxiliary grid can then in particular be an auxiliary grid made up of triangles, preferably isosceles triangles, for example equilateral triangles.

It can be particularly advantageous if the structural element assembly has openings. The openings can be openings that extend from one side of the structural element assembly to another side of the structural element assembly. The openings can extend, for example, from the adjustment side to the back. It can be particularly advantageous if the openings are each located between several adjustment elements.

It can be particularly advantageous if the openings are located entirely or partially within the triangles or squares of the auxiliary grid and/or the centers of the cross sections of the openings are located within the triangles or squares of the auxiliary grid.

Openings can be located, for example, in every third, every second or every square or triangle of the auxiliary grid.

It can be advantageous if the openings are located in every sixth, every fourth, every third, every second or every triangle of the auxiliary grid.

It can be advantageous if an intra-group distance, measurable in a first direction, between two adaptation elements belonging to the same group is equal to an intermediate distance, measurable in the first direction, between two adaptation elements belonging to different groups.

It may be preferred if an intra-group distance, measurable in a second direction, between two adaptation elements belonging to the same group is the same as an intermediate distance, measurable in the second direction, between two adaptation elements belonging to different groups.

It may be preferred if the first direction and the second direction form an angle of 10° to 90°, preferably 20° to 90°, for example 25° to 90°, with respect to one another.

The first direction may preferably be a direction of the first set of straight lines. The second direction may preferably be a direction of the second set of straight lines.

It may be advantageous if the supporting structure element has an adaptation side and a rear side opposite the adaptation side and the adaptation element connecting section extends partially or completely along the adaptation side.

It may be advantageous if the supporting structure element has an adaptation side and a rear side opposite the adaptation side and the adaptation element connecting section extends partially or completely along the rear side.

For example, the first adaptation element group connecting portion and/or the second adaptation element group connecting portion may extend partially or completely along the adaptation side.

For example, the first adjustment element group connecting portion and/or the second adjustment element group connecting portion may extend partially or completely along the back side.

It is possible that a part of the adjustment element connecting portion, for example a part of the first adjustment element group connecting portion and/or a part of the second adjustment element group connecting portion, extends along the adjustment side and another part of the adjustment element connecting portion, for example another part of the first adjustment element group connecting portion and/or another part of the second adjustment element group connecting portion, extends along the back side.

Between a part extending along the adaptation side and a part extending along the rear side, the respective connecting section can be passed through the supporting structure element, for example through a connecting opening of the supporting structure element.

It can be advantageous if the structural element assembly has an opening. The opening can be a passage. The opening can extend from one side of the support structure element to another side of the support structure element. The opening can extend, for example, from the adaptation side of the support structure element to the rear side of the support structure element.

It can be particularly advantageous if an opening is formed between several adaptation elements that belong to the same group of adaptation elements.

It can be advantageous if the opening has an opening surface. The opening surface can, for example, be a surface of an opening's inner wall.

It can be advantageous if the structural element assembly has a projection area in which the structural element assembly projects beyond the supporting structure surface. Preferably, the projection area is not an area of an adaptation element, in particular not the projection zone.

It can be advantageous if the overhang area reaches up to the opening, is arranged at the opening or partially or completely surrounds the opening.

It can be particularly advantageous if the adaptation element connecting section extends around the opening.

It can be particularly advantageous if the adaptation element connecting section extends around the opening or along the opening which is formed between a plurality of adaptation elements.

It can be particularly advantageous if the adaptation element connecting section reaches up to the opening.

Preferably, the adaptation element connecting portion may form part of the opening surface.

It can be particularly advantageous if a further opening is formed between several adaptation elements that belong to different groups of adaptation elements.

It can be particularly advantageous if the structural element composite has a plurality of openings, in particular at least 4 openings, preferably at least 9 openings, e.g. at least 16 openings.

It may be advantageous if the openings are arranged regularly, e.g. as described herein with reference to the auxiliary grid, in particular with reference to triangles or squares of the auxiliary grid.

It can be particularly advantageous if the supporting structure element and the adaptation element are positively connected to one another.

Preferably, the supporting structure element and the adaptation element can optionally be additionally connected to one another in a force-fitting and/or material-fitting manner.

For example, the supporting structure element and the adaptation element can optionally be additionally connected to each other in a force-fitting manner.

For example, the supporting structure element and the adaptation element can optionally be additionally connected to each other in a material-locking manner.

The structural element composite can preferably be a structural element composite obtainable by the method described herein. The structural element composite can preferably be a structural element composite obtained by the method described herein. The structural element composite can preferably be a structural element composite produced by the method described herein. The structural element composite can be, for example, the plastic component, wherein the structural element composite can preferably be flat and/or plate-shaped and/or grid-shaped.

The object is achieved according to the invention by a method according to the relevant independent claim.

The method is a method for producing a structural element composite. The method can, for example, be a method for producing a plastic component.

The structural element composite can preferably be flat and/or plate-shaped and/or grid-shaped. The structural element composite can preferably be flat and plate-shaped. The structural element composite can preferably be flat and grid-shaped.

It may be advantageous if the structural element composite described in connection with the method is a structural element composite according to the invention described herein.

It can be particularly advantageous if the structural element composite obtained by the process for producing a structural element composite is a structural element composite according to the invention described herein.

In the method for producing the structural element composite, an adaptation element precursor is attached to a supporting structure element in a form-fitting, force-fitting and/or material-fitting manner in an attachment step in a tool.

The tool can in particular be a shaping tool, for example an injection molding tool.

The adaptation element precursor is preferably attached to the supporting structure element in a material-to-material manner.

It can be particularly advantageous if the adaptation element precursor is injection-molded onto the supporting structure element.

In an expansion step, a volume of the adaptation element precursor is increased in an expansion section of the adaptation element precursor and an adaptation element of the structural element composite is generated from the adaptation element precursor.

It can be particularly advantageous if the volume of the adaptation element precursor in the expansion section is increased to such an extent that a compression hardness of the adaptation element produced is at least approximately 2 kPa, preferably at least approximately 5 kPa, in particular at least approximately 10 kPa and/or at most approximately 100 kPa, preferably at most approximately 80 kPa, for example at most approximately 50 kPa.

In one embodiment, the compression hardness may be, for example, approximately 25 kPa.

For example, to determine the compression hardness, the adjustment element is acted upon in such a way that it is reduced by 40% of its initial size, especially at a temperature of 20 °C.

As is known, in common test procedures for measuring compression hardness, a test specimen is compressed between two plates and the force required to compress this test specimen to a certain amount of its original height is measured. This common test procedure can be slightly adapted to determine the compression hardness of the adaptation element.

The measurement of the compression hardness of the adaptation element is in particular a compression hardness of the adaptation element measured directly on the structural element composite. The compression hardness can in particular be measured orthogonally to the plane of extension. When determining the compression hardness of an adaptation element, an area of a structural element composite that has the adaptation element and is completely tempered to 20 °C can serve as a test specimen and this area can be arranged between the two plates of a test device for measuring the compression hardness.

When measuring the compression hardness, the two plates of the test device are moved towards each other until the height of a portion of the adjustment element resting on the supporting structure element is reduced by 40%. To calculate the compression hardness, the force applied for this compression is divided by a base area of the adjustment element, which can be measured parallel to the extension plane.

It can be advantageous if the tool has a movable expansion element. It can be advantageous if, in the expansion step to increase the volume of the adaptation element precursor, a position of the expansion element is changed so that an expansion space is created that reaches up to the expansion section.

The position of the expansion element can be changed, for example, by a translational movement of the expansion element.

Preferably, the expansion element can be guided on the tool by means of a guide element, thus enabling a translational movement of the expansion element.

It may be particularly advantageous if the volume of the adaptation element precursor in the expansion section of the adaptation element precursor is increased by physical and/or chemical foaming, e.g. by physical and/or chemical foaming in the expansion space.

It may be advantageous if the adaptation element precursor is made entirely or partially from a foamable plastic material.

Advantageously, the production of the adaptation element can be accompanied by foaming of the expansion section in the expansion space. Preferably, the adaptation element precursor can be produced completely from the foamable plastic material and the production of the adaptation element can be accompanied by foaming of the expansion section in the expansion space.

It may be advantageous if the volume of the adaptation element precursor is increased in the expansion section and a density gradient is established in the resulting adaptation element, wherein a density of the resulting adaptation element in a core zone of the adaptation element is lower than a density of the resulting adaptation element in a surface zone of the adaptation element.

It may be advantageous if the adaptation element has a skin formed from the plastic material in one or the surface zone and the adaptation element has a foam zone formed from the plastic material in one or the core zone.

Possible compositions of the plastic material have been described in connection with the structural element composite according to the invention described here. In particular, the information provided in this context can also apply to the plastic material described in connection with the method according to the invention.

Preferably, the support structure element can be produced in a support structure forming zone. The support structure element can be produced, for example, in a support structure injection molding zone.

The support structure element can be produced in the support structure forming zone, for example in the support structure injection molding zone, preferably from a plastic mass.

It may be preferred if the support structure forming zone is provided in the tool and the attachment of the adaptation element precursor in the tool takes place after the production of the support structure element.

It may be advantageous if the adaptation element precursor is attached before the produced supporting structure element is cooled to a temperature of less than 45 °C.

It can be particularly advantageous if the adaptation element precursor is attached before the produced supporting structure element is cooled to a temperature of less than 50 °C.

It may be advantageous if the adaptation element precursor is attached after the produced supporting structure element has been cooled to a temperature of at most 85 °C.

It can be particularly advantageous if the adaptation element precursor is attached after the produced supporting structure element has been cooled to a temperature of at most 75 °C.

It can be particularly advantageous if the adaptation element precursor is attached after the produced supporting structure element has been cooled to a temperature of 45°C to 85°C.

For example, the adaptation element precursor can be attached after cooling the produced support structure element to a temperature of 50°C to 75°C.

The respective temperature of the support structure element can in particular be a surface temperature of the support structure element in a surface region of the support structure element to which the adaptation element precursor is attached, e.g. molded.

The cooling may be a cooling from a higher forming temperature prevailing in the supporting structure forming zone.

The cooling may be a cooling from a higher support structure molding temperature prevailing in the support structure molding zone.

The cooling can be an active cooling, which can be combined, for example, with a circulation of a cooling medium.

The cooling can be passive cooling, which can, for example, be associated with the release of heat to a surrounding medium, e.g. air, which is not circulated.

Alternatively, the support structure element can be introduced into the tool and the adaptation element precursor can be attached to the tool after the support structure element has been introduced.

It can be advantageous if the adaptation element precursor belongs to an adaptation element precursor group. Preferably, a precursor group space can be formed in the tool on one side or on both sides of the support structure element, in particular on an adaptation side of the support structure element and/or on a rear side of the support structure element, and the adaptation element precursor group can be produced in the precursor group space or through the precursor group space.

It may be preferred if the adaptation element precursor group is produced from the foamable plastic material. For example, the adaptation element precursor group can be produced from the foamable plastic material by injection molding. The adaptation element precursor group can be injection molded onto the supporting structure element in the precursor group space.

The tool can, for example, have a movable release element, wherein in the tool on one side or on both sides of the support structure element, in particular on an adaptation side of the support structure element and/or on a rear side of the support structure element, the precursor group space is released by a movement of the release element into a release position and the adaptation element precursor group is generated in the precursor group space or through the precursor group space.

It can be advantageous if the adaptation element precursor belongs to an adaptation element precursor group, wherein the adaptation element precursor is a first adaptation element precursor and a second adaptation element precursor belongs to the adaptation element precursor group, wherein the foamable plastic material is fed from a common feed zone and is passed on in a dividing, e.g. branching, manner to produce the adaptation element precursors of the adaptation element precursor group.

It may be advantageous if a distance of the feed zone to an adaptation element precursor along a plastic material guide direction leading from the feed zone to this adaptation element precursor is greater than another distance of the feed zone to another adaptation element precursor along a plastic material guide direction leading from the feed zone to this other adaptation element. ment precursor leading other plastic material guide direction.

A cross-section of a plastic material guide channel leading from the feed zone to the one adaptation element precursor may be larger than another cross-section of another plastic material guide channel leading from the feed zone to the other adaptation element precursor.

For example, a mean cross-section of a plastic material guide channel leading from the feed zone to the one adaptation element precursor may be larger than another mean cross-section of another plastic material guide channel leading from the feed zone to the other adaptation element precursor.

For example, a smallest cross-section of a plastic material guide channel leading from the feed zone to the one adaptation element precursor may be larger than another smallest cross-section of another plastic material guide channel leading from the feed zone to the other adaptation element precursor.

Of course, features described in connection with an object according to the invention can also form features of another object according to the invention described herein. Objects according to the invention are in particular the structural element composite, for example the plastic component, and the method for producing a structural element composite, for example a plastic component.

Further preferred features and/or advantages of the invention are the subject of the following description and the drawings of embodiments.

• 1: einen schematisch dargestellten Strukturelement-Verbund in perspektivischer Darstellung;
• 2: einen Schnitt durch den Strukturelement-Verbund aus 1 entlang der Linie II-II;
• 3: einen Ausschnitt eines Strukturelement-Verbunds mit viereckigem Anpassungselement;
• 4: einen Ausschnitt aus einem Strukturelement-Verbund mit dreieckigem Anpassungselement;
• 5: einen Ausschnitt aus einem Strukturelement-Verbund mit birnenförmigen Anpassungselement;
• 6: einen Ausschnitt aus einem Strukturelement-Verbund in perspektivischer Darstellung;
• 7: einen Ausschnitt eines Strukturelement-Verbunds mit einem Anpassungselement;
• 8: einen Schnitt durch den Strukturelement-Verbund aus 7 entlang der Linie VII-VII;
• 9: einen weiteren Ausschnitt aus einem Strukturelement-Verbund mit einem Anpassungselement;
• 10: einen Schnitt durch den Strukturelement-Verbund aus 9 entlang der Linie IX-IX;
• 11: einen Schnitt durch einen weiteren Strukturelement-Verbund;
• 12: einen Schnitt durch einen weiteren Strukturelement-Verbund;
• 13: einen Ausschnitt eines weiteren Strukturelement-Verbunds;
• 14: einen Ausschnitt eines weiteren Strukturelement-Verbunds in perspektivischer Darstellung;
• 15: einen Ausschnitt eines weiteren Strukturelement-Verbunds in perspektivischer Darstellung;
• 16: einen Ausschnitt eines weiteren Strukturelement-Verbunds in perspektivischer Darstellung;
• 17-19: Illustrationen zur Einbringung einer Öffnung in einen Ausschnitt des Strukturelement-Verbunds aus 16;
• 20: einen Ausschnitt eines gitterförmigen Strukturelement-Verbunds; und
• 21-25: ein erfindungsgemäßes Verfahren.

The drawings show:

• 1 : a schematically represented structural element composite in perspective view;
• 2 : a section through the structural element composite of 1 along line II-II;
• 3 : a section of a structural element composite with a square adaptation element;
• 4 : a section of a structural element composite with a triangular adaptation element;
• 5 : a section of a structural element composite with pear-shaped adaptation element;
• 6 : a section of a structural element composite in perspective view;
• 7 : a section of a structural element composite with an adaptation element;
• 8 : a section through the structural element composite of 7 along line VII-VII;
• 9 : another section of a structural element composite with an adaptation element;
• 10 : a section through the structural element composite of 9 along the line IX-IX;
• 11 : a section through another structural element composite;
• 12 : a section through another structural element composite;
• 13 : a section of another structural element composite;
• 14 : a section of another structural element composite in perspective view;
• 15 : a section of another structural element composite in perspective view;
• 16 : a section of another structural element composite in perspective view;
• 17-19 : Illustrations for the introduction of an opening into a section of the structural element composite made of 16 ;
• 20 : a section of a lattice-shaped structural element composite; and
• 21-25 : a method according to the invention.

Identical or functionally equivalent elements are provided with the same reference numerals in all figures.

The 1 shows a structural element composite 100. The structural element composite 100 is a plastic component 102.

The structural element composite 100 comprises a supporting structure element 104. The supporting structure element 104 is a plastic supporting structure element 106.

The structural element assembly 100 comprises a plurality of adaptation elements 108 fixed to the supporting structure element 104. Only a portion of the adaptation elements 108 are provided with reference symbols.

The adjustment elements 108 are plastic adjustment elements 110.

The adaptation elements 108 have overhang zones 112. In the overhang zones 112, the adaptation elements 108 protrude beyond the supporting structure elements 104.

The support structure element 104 has an adaptation side 114 and a rear side 116 opposite the adaptation side 114.

The adjustment elements 108 are arranged regularly. The support structure element 104 has openings 118. The openings 118 are also arranged regularly. The openings 118 are each surrounded by several adjustment elements 108.

The 2 shows a section through the structural element assembly 100 from the 1 .

The 2 shows that the openings 118 are passages 120 that extend through the support structure element 104 from the adaptation side 114 to the back side 116.

The supporting structure element 104 and the adaptation element 108 are connected to each other in a form-fitting manner. In addition to the 2 In addition to the positive connection 122 shown, there may be a force-fitting connection 124 and/or a material-fitting connection 126 between the supporting structure element 104 and the adaptation element 108.

The adaptation element 108 has an adaptation surface 128. The adaptation surface 128 is softer than a support structure surface 130 of the support structure element 104.

The adjustment element 108 has an adjustment portion 132. The adjustment portion 132 is a foamed portion 134.

The adaptation element 108 is a plastic adaptation element 110 made of a plastic material 136. In the example shown here, the adaptation element material 138 is therefore a plastic material 136.

The adaptation element 108 has a compact portion 140. The adaptation element 108 also has a connection zone 142. The positive connection 122 between the support structure element 104 and the adaptation element 108 is a positive connection 122 mediated by the connection zone 142. At least a part of the compact portion 140 lies in the connection zone 142.

The 2 The positive connection 122 shown comprises a section 121 of the support structure element 104 which extends between sections 123 of the adaptation element 108. The section 121 of the support structure element 104 extends between a section 123 of the adaptation element 108 arranged on an adaptation side 114 of the support structure element 104 and a section 123 of the adaptation element 108 arranged on the rear side 116 of the support structure element 104.

While the 1 and 2 Adjustment elements 108 with round cross-section illustrate the 3 to 5 that the invention is not limited in terms of the shape of the adaptation elements. 3 shows a square adjustment element 144. The corners of the square adjustment element 144 are rounded.

The 4 shows a triangular adjustment element 146. The corners of the triangular adjustment element 146 are rounded.

The 5 shows a pear-shaped adjustment element 148.

In the 3 to 5 the viewer's line of sight is directed towards the adaptation side 114 of the respective supporting structure element 104. The adaptation elements 144, 146 and 148 shown there have their respective shape in particular in a cross-section lying parallel to an extension plane 150 of the structural element assembly 100.

The one in the 1 The structural element assembly 100 shown is flat. In the 1 the extension plane 150 is indicated by dashed lines.

The 6 shows a section of another structural element assembly 100. The structural element assembly 100 shown there is also a plastic component 102. Only a small section is shown, which has four openings 118 and an adjustment element 108. The adjustment element 108 shown there is a triangular adjustment element 146. Of the 1 The adjustment elements 108 shown in the 6 The adaptation element 108 shown also differs in that it has no projection zone 112. It does not protrude beyond the support structure surface 130.

The 7 shows another section of a structural element composite 100. The 7 The structural element composite 100 shown is a plastic component 102.

Shown in the 7 a section of the structural element composite 100 with an adaptation element 108.

The figure also shows a support structure surface 130 surrounding the adaptation element 108.

The 8 shows a cross-section through the 7 along the line VII-VII. From the 8 The cut shown makes it clear that the 7 shown adaptation element 108 has an adaptation surface 128. The 8 shows that a first adaptation surface 152 merges into a recess 156 via a shoulder 154. A second adaptation surface 158 is formed in the recess 156. A third adaptation surface 160 also merges into the recess 156 via a shoulder 154, in which the second adaptation surface 158 is formed.

The 9 shows a section of a structural element composite 100. The 9 The structural element composite 100 shown is a plastic component 102. Also shown in 9 a section of the structural element assembly 100, including an adaptation element 108. The adaptation element 108 is a triangular adaptation element 146. The adaptation element 108 has a first adaptation surface 152 and a second adaptation surface 158. The adaptation element 108 also has an elevation 162. At the elevation 162, the adaptation element 108 is more raised than at the two adaptation surfaces 152 and 158 relative to the support structure surface 130, which extends along the adaptation side 114. This is particularly evident from the 10 clearly visible, which is a cross-section through the 9 along the line IX-IX.

Also in the 9 and 10 The adjustment element shown has a shoulder 154. At the shoulder, the first adjustment surface 152 merges into the second adjustment surface 158.

The 9 and 10 The elevation 162 shown is a wall element 165.

The 11 shows a section through a structural element composite 100. The structural element composite 100 is a plastic component 102. The structural element composite 100 is flat and plate-shaped.

The one in the 11 The structural element composite 100 shown comprises groups 164 of adjustment elements 108. The group 164 of adjustment elements 108 shown in the 11 shown in section is a first group 166 of adaptation elements 108.

One of the 11 One of the adjustment elements 108 shown is a first adjustment element 168. Another of the adjustment elements 108 shown in the 11 The adjustment elements 108 shown is a second adjustment element 170. The adjustment element 170 shown in the 11 The structural element assembly 100 shown comprises an adaptation element connecting section 180.

The adjustment element connecting section 180 connects the first adjustment element 168 to the second adjustment element 170.

The first adjustment element 168, the second adjustment element 170 and the adjustment element connecting portion 180 connecting the first adjustment element 168 to the second adjustment element 170 is a one-piece plastic element 182. The first adjustment element 168, the second adjustment element 170 and the adjustment element connecting portion 180 connecting the first adjustment element 168 to the second adjustment element 170 is made of a continuous plastic material 184.

The first adaptation element 168, the second adaptation element 170 and the adaptation element connecting section 180 connecting the first adaptation element 168 to the second adaptation element 170 is, in the example shown here, a one-piece plastic element 182 made from a continuous plastic material 184 by injection molding.

The two in the 11 The adjustment elements 108 shown, i.e. the first adjustment element 168 and the second adjustment element 170, each have an adjustment section 132. The respective adjustment section 132 is a foamed section 134.

The 11 The support structure element 104 shown is connected to the two adjustment elements 108, i.e. to the first adjustment element 168 and the second adjustment element 170, in each case as described in connection with the 2 for the adaptation element 108 shown there and the supporting structure element 104 shown there.

Also in the 11 The support structure element shown has an adaptation side 114 and a rear side 116 opposite the adaptation side. The adaptation element connecting section 180 extends along the adaptation side 114.

The 12 shows a section of a structural element composite 100. As in the 11 is also in the 12 a section of the structural element composite 100 shown.

The 12 shows a group 164 of adjustment elements 108.

Also in the 12 The support structure element 104 shown has an adaptation side 114 and a rear side 116. In the 12 In the embodiment shown, the adaptation element connecting portion 180 extends along the rear side 116.

The 13 shows another structural element composite 100.

The one in the 13 The further structural element composite 100 shown is a plastic component 102. The structural element composite 100 shown there is flat and plate-shaped.

The one in the 13 The structural element assembly 100 shown comprises a supporting structure element 104, of which 13 only a section is shown. The 13 The support structure element 104 shown has an adaptation side 114 and a rear side 116. In the 13 In the representation of the structural element assembly 100 shown there, the adaptation side 114 of the supporting structure element 104 faces the viewer.

Regions of the structural element assembly 100 covered by the supporting structure element 104 are shown in dashed lines. In particular, adaptation element connecting sections 180 that extend along the rear side 116 are shown in dashed lines.

The one in the 13 The structural element assembly 100 shown comprises an adjustment element 108 fixed to the support structure element 104. The adjustment element 108 is a first adjustment element 168. The structural element assembly 100 comprises a second adjustment element 170, a third adjustment element 172, a fourth adjustment element 174, a fifth adjustment element 176 and a sixth adjustment element 178.

The one in 13 The structural element assembly 100 shown comprises an adaptation element connecting portion 180. The adaptation element connecting portion 180 connects the first adaptation element 168 to the second adaptation element 170. The adaptation element connecting portion 180 is connected to the first adaptation element 168, the second adaptation element 170, the third adaptation element 172, the fourth adaptation element 174, the fifth adaptation element 176 and the sixth adaptation element 178.

The one in the 13 The structural element composite 100 shown comprises groups 164 of adaptation elements 108. The first adaptation element 168, the second adaptation element 170, the third adaptation element 172, the fourth adaptation element 174, the fifth adaptation element 176 and the sixth adaptation element 178 belong to a first group 166 of adaptation elements 108.

One of the 13 shown adjustment element connecting portions 180 is a first adjustment element group connecting portion 186.

The structural element composite 100, which is in the 13 , further comprises a second adaptation element group connecting portion 188. Second adaptation element group connecting portion 188 connects a first adaptation element 168 of a second group 190 of adaptation elements 108 to the second adaptation element 170 of the second group 190 of adaptation elements 108.

The second adjustment element group connecting portion 188 is connected to the first adjustment element 168, the second adjustment element 170, the third adjustment element 172, the fourth adjustment element 174, the fifth adjustment element 176 and the sixth adjustment element 178 of the second group 190 of adjustment elements 108.

In the 13 In the structural element composite 100 shown, the adaptation elements 108 of several groups 164 of adaptation elements 108 are arranged regularly.

An intra-group distance 194, measurable in a first direction 192, between two adaptation elements 108 that belong to the same group 164 is the same size as an intermediate distance 196, measurable in the first direction 192, between two adaptation elements 108 that belong to different groups 164. The intra-group distance 194, measurable in the first direction 192, between two adaptation elements 108 is an intra-group distance 194 measurable between the first adaptation element 168 and the second adaptation element 170 of the first group 166. The intermediate distance 196, measurable in the first direction 192, between two adaptation elements 108 is an intermediate distance 196 measurable between the first adaptation element 168 of the first group 164 and the sixth adaptation element 178 of the second group 190.

An intra-group distance 200, measurable in a second direction 198, between two adaptation elements 108 that belong to the same group 164 is the same size as an intermediate distance 202, measurable in the second direction 198, between two adaptation elements 108 that belong to different groups 164. The intra-group distance 200, measurable in the second direction 198, between two adaptation elements 108 is an intra-group distance 200 between the second adaptation element 170 and the fourth adaptation element 174 of the first group 166. The intermediate distance 202, measurable in the second direction 198, between two adaptation elements 108 is the intermediate distance 202 between the fourth adaptation element 174 of the first group 166 and the first adaptation element 168 of the second group 190.

In the 13 In the structural element composite 100 shown, the first direction 192 and the second direction 198 form an angle 204 of approximately 63° with respect to one another.

The one in the 13 The structural element assembly 100 shown has a plurality of openings 118, which can in particular be passages 120. To improve clarity, 13 the openings are not shown. It can be particularly advantageous if a portion of the openings 118 is formed between a plurality of adaptation elements 108 that belong to the same group of adaptation elements. It can also be advantageous if a further portion of the openings 118 is formed between a plurality of adaptation elements 108 that belong to different groups 164 of adaptation elements 108.

The openings 118 can therefore be arranged just as regularly as those in the 13 adjustment elements shown 108.

The 14 shows a section of another structural element composite 100. The structural element composite 100 is a plastic component 102. The structural element composite 100 is flat and plate-shaped.

The structural element composite 100 comprises a supporting structure element 104. The supporting structure element 104 is a plastic supporting structure element 106.

The structural element assembly 100 comprises a plurality of adaptation elements 108 fixed to the supporting structure element 104. The adaptation elements 108 are plastic adaptation elements 110.

The supporting structure elements 104 and the adaptation elements 108 are connected to each other in a form-fitting, force-fitting or material-fitting manner, whereby the type of connection is determined by the 14 not apparent.

The adjustment elements 108 of the 14 shown structural element composite 100 each have an adaptation section 132. The adaptation sections 132 are foamed sections 134.

In the section of the structural element composite 100 which is in the 14 As shown, the structural element assembly 100 has an opening 118. The opening 118 extends from one side of the support structure element 104 to another side of the support structure element. The opening 118 extends from the adaptation side 114 of the support structure element to the rear side 116 of the support structure element. The 14 The opening 118 shown is a passage 120. The opening 118 is formed between a plurality of adaptation elements 108. It is conceivable that the plurality of adaptation elements 108 between which the opening 118 is formed belong to the same group of adaptation elements or to different groups of adaptation elements.

The opening 118 has an opening surface 206. The opening surface 206 may, for example, be a surface of an opening inner wall 208.

The structural element composite 100 can have a projection region 210. In the projection region 210, the structural element composite 100 can project beyond the supporting structure surface 130. In the 14 The projection region 210 surrounds the opening 118 shown in FIG.

The 15 shows a section of another structural element composite 100.

The one in the 15 The structural element assembly 100 shown comprises a supporting structure element 104 and a plurality of adaptation elements 108 fixed to the supporting structure element. The 15 The structural element assembly 100 shown also has an opening 118. The opening 118 is a passage 120.

The opening 118 and the adaptation elements 108 are designed and arranged relative to each other as is necessary with regard to the 14 was described.

• Der in der 15 gezeigte Strukturelement-Verbund 100 umfasst zwei Anpassungselemente-Verbindungsabschnitte 180. Der in der 15 weiter links dargestellte Anpassungselemente-Verbindungsabschnitt 180 verbindet ein erstes Anpassungselement 168 und ein zweites Anpassungselement 170 einer in der 15 weiter links dargestellten ersten Gruppe 166 von Anpassungselementen 108.

The following deviations exist:

• The one in the 15 The structural element assembly 100 shown comprises two adaptation element connecting sections 180. The 15 The adaptation element connecting section 180 shown further to the left connects a first adaptation element 168 and a second adaptation element 170 of a 15 the first group 166 of adjustment elements 108 shown further to the left.

The one in the 15 The adjustment element connecting section 180 shown further to the right connects a first adjustment element 168 and a second adjustment element 170 of a second group 190 of adjustment elements 108.

In the 15 In the structural element assembly 100 shown, the two adaptation element connecting sections 180 each form a part of the overhang region 210, which reaches up to the opening 118, is arranged at the opening 118 and surrounds the opening 118. The two adaptation element connecting sections 180 extend along the opening 118, which is between the four in the 15 shown adaptation elements 108. The adaptation element connecting sections 180 form part of the opening surface 206.

The 15 The opening 118 shown is an opening 118 between several adjustment elements 108, which belong to different groups of adjustment elements 108. Because the two in the 15 The adjustment elements 108 shown further to the left belong to a first group 166 of adjustment elements and the two in the 15 The adjustment elements 108 shown further to the right belong to a second group 190 of adjustment elements.

The 16 shows a section of another structural element composite 100. The 16 The structural element assembly 100 shown comprises a supporting structure element 104. It also comprises adaptation elements 108 fixed to the supporting structure element 104.

The one in the 16 The structural element assembly 100 shown comprises groups 164 of adaptation elements 108. From a 16 In the group 165 of adjustment elements 108 shown on the left, only two adjustment elements 108 can be seen. This group 164 can be understood as a first group 166 of adjustment elements 108. From a group shown in the 16 In the group 164 of adjustment elements 108 shown in the middle, a first adjustment element 168, a second adjustment element 170, a third adjustment element 172, a fourth adjustment element 174 and a fifth adjustment element 176 are shown. Of a third group 212 of adjustment elements 108 adjoining to the right, only a first adjustment element 168 can be seen.

The three groups 166, 190 and 212 of adjustment elements 108 each include five adjustment elements 108, whereby in the 16 shown section of the structural element composite 100, only all five adaptation elements 168, 170, 172, 174 and 176 of the second group 190 can be seen.

The one in the 16 The structural element assembly 100 shown comprises a plurality of adaptation element connecting sections 180. Each of the adaptation element connecting sections 180 is connected to the first, second, third, fourth and fifth adaptation elements that belong to a respective group 164 of adaptation elements 108.

The 16 The adjustment elements shown are arranged regularly. A part of the adjustment elements 108 lies on a first straight line 214. Another part of the adjustment elements 108 lies on a second straight line 216. Another part of the adjustment elements 108 lies on a third straight line 218. The three straight lines 214, 216 and 218 are in the 16 shown in dashed lines.

The 16 The adaptation elements 108 shown are derived from adaptation element precursors 254, as explained in connection with the method described herein. The groups 164 of adaptation elements are formed from adaptation element precursor groups. In the 16 A common feed zone 266 is indicated by dashed lines. It extends from a side facing away from the viewer into the support structure element 104. To produce the 16 A foamable plastic material can be fed from the common feed zone 266 to the structural element assembly 100 shown and can be further divided, e.g. branched, to produce the adaptation element precursors 254 of an adaptation element precursor group. This forms an adaptation element connecting section 180. Subsequently, a 22 described expansion step 256 can be carried out to obtain from each adaptation element precursor 254 a 16 shown adaptation element 108 of a structural element composite.

In the 16 three of the adaptation elements 108 are encircled by a dashed line which is essentially triangular. The section of the structural element assembly 100 encircled by this dashed line from 16 is shown schematically in the 17 to 19 shown. The 17 to 19 illustrate the difficulties that can arise when, on the one hand, there is a desire to provide an opening 118 between several adaptation elements 108, and on the other hand several adaptation elements 108 are to be connected to one another via adaptation element connecting sections 180. In particular, if larger numbers of adaptation elements 108 are to be connected by means of adaptation element connecting sections 180, overlapping areas 220 can result in which adaptation element connecting sections 180 can extend through openings 118. This shows 17 .

The 18 illustrates a possibility for solving this problem. The adaptation element connecting section 180 shown there extends around the opening 118. The adaptation element connecting section 180 shown there reaches up to the opening. The opening 118 has an opening surface 206. The 18 The adaptation element connecting portion 118 shown forms part of the opening surface 206.

The 19 illustrates another possibility to solve the problem mentioned. The 19 shows an adjustment element connecting section 180 that does not reach as far as the opening 118. The adjustment element connecting section 180 shown there extends around the opening 118.

The 20 shows a section of another structural element composite 100. The 20 The structural element composite 100 shown is a plastic component 102. The structural element composite 100 is flat and lattice-shaped.

The one in the 20 The structural element composite 100 shown comprises a support structure element 104. The support structure element 104 is a plastic support structure element 106 which is flat and lattice-shaped.

At the 20 Several adjustment elements 108 are fixed to the support structure element 104 shown. The support structure element 104 and the adjustment elements 108 are connected to one another in a form-fitting and/or force-fitting and/or material-fitting manner. The type of connection is determined from the 20 not prominent.

The lattice-shaped support structure element 104 has support struts 222. Support struts 222 border on openings 118 of the structural element assembly 100.

The one in the 20 The structural element assembly 100 shown comprises adaptation element connecting sections 180. One of the adaptation element connecting sections 180 is in the 20 shown section. The adjustment element connecting section 180 is connected to the first adjustment element 168, to the second adjustment element 170, to the third adjustment element 172, to the fourth adjustment element 174 and to the fifth adjustment element 176.

In the 20 In the structural element assembly 100 shown, the adaptation element connecting section 180 extends from the first adaptation element 168 and the second adaptation element 170 across the third adaptation element 172 to the fourth adaptation element 174 and the fifth adaptation element 176.

The 20 The openings 118 shown are each formed between a plurality of adaptation elements 108 which belong to the same group 164 of adaptation elements 108.

The openings 118 each have an opening surface 206. The respective opening surface 206 is a surface of the respective opening inner wall 208.

20 also shows that the structural element assembly 100 shown there has a projection region 210 in which the structural element assembly 100 projects beyond the support structure surface 130. A surface of the support struts 222 aligned with the adaptation side 114 forms the support structure surface 130.

In the structural element composite 100, which is shown in the 20 As shown, the adjustment element connecting portion 180 extends along a plurality of openings 118, each formed between a plurality of adjustment elements 108.

The adaptation element connecting section 180 extends there up to the respective opening 118.

The 21 shows a tool 224 in a schematic representation. The tool 224 is a shaping tool 226. It is an injection molding tool 228.

The tool 224 comprises a plurality of forming units 230, a first forming unit 232 and a second forming unit 234. The two forming units 230, 232, 234 can be regarded as mold halves 236 of the tool 224.

The 21 The tool 224 shown can be used to produce a structural element bundle 100, e.g. a plastic component 102.

In particular, the tool 224 can be used to carry out a method for producing a structural element composite 100, e.g. a plastic component 102. This is described in the 21 to 25 illustrated.

The first forming unit 232 has a feed channel 238 for feeding a plastic melt 240 into the tool 224.

The tool 224 has a plurality of movable expansion elements 242.

The movable expansion elements 242 are integrated into the second forming unit 234. The movable expansion elements 242 are guided in the second forming unit 234 such that the positions of the expansion elements 242 can be changed.

The movable expansion elements 242 are components of an expansion device 244. As components of the expansion device 244, the expansion elements 242 shown are movable with one another and together with an expansion element carrier 246.

The expansion device 244 is arranged on the second shaping unit 234 by means of a guide element 248 such that the guide element 248 is received in a guide 250. This can in particular enable a movement of the expansion device 244 relative to the second shaping unit 234 by moving the guide element 248 into the guide 250 or out of the guide 250.

In an attachment step 252, an adaptation element precursor 254 is attached to a support structure element 104 in the tool 224.

The adaptation element precursor 254 can be attached in a form-fitting, force-fitting and/or material-fitting manner, for example by injection molding. 21 illustrates the attachment step 252.

In an expansion step 256, a volume of the adaptation element precursor 254 is increased in an expansion section 258 of the adaptation element precursor 254 and an adaptation element 108 of the structural element composite 100 is produced from the adaptation element precursor 254. The 22 illustrates the expansion step 256.

To form a recess 156 of an adaptation element 108, a projection can be formed on the expansion element 242, which prevents the foamable plastic material from reaching the area of the intended recess 156.

In the expansion step 256, in order to increase the volume of the adaptation element precursor 254, a position of the expansion elements 242 is changed such that expansion spaces 260 are created that reach up to the expansion sections 258.

The volumes of the adaptation element precursors 254 are increased in the respective expansion section 258 of the adaptation element precursors 254 by physical and/or chemical foaming into the expansion space 260.

The adaptation element precursors 254 and the adaptation elements 108 made from them are made from a foamable plastic material. The production of the adaptation elements 108 is accompanied by foaming of the expansion sections 258 in the expansion spaces 260.

In principle, it is conceivable that the foamable plastic material 21 to 25 shown plastic melt 240 and the foamable plastic material is fed via the feed channel 238 also shown there. Alternatively, the plastic melt fed via the feed channel 238 can be used to produce the support structure element in the same tool 224. The 23 illustrates an opening step 262 in which the tool 224 is opened. For this purpose, the second forming unit 234 was moved away from the first forming unit 232.

The 24 and 25 illustrate a process for removing the structural element assembly 100 from the second forming unit 234. To do this, the expansion device 244 with the movable expansion elements 242 and the expansion element carrier 246, which also belongs to the expansion device, can first be moved back into the 21 shown starting position. Since the adaptation element precursors 254 have been expanded in the meantime and converted into adaptation elements 108, they take up a larger space. Consequently, the return of the movable expansion elements 242 to the starting position causes the support structure element 104 to be lifted out of the second forming unit 234. This shows the 24 .

By means of further removal elements 264, the produced structural element composite 100 can be further removed from the second forming unit 234 be lifted out as far as this is necessary for removing the structural element assembly 100 from the opened tool 224 ( 25 ).

list of reference symbols

100

structural element composite

102

plastic component

104

supporting structure element

106

plastic supporting structure element

108

adjustment element

110

plastic adjustment element

112

overhang zone

114

customization page

116

back

118

openings

120

culverts

121

section of the supporting structure element

122

positive connection

123

section of the adjustment element

124

force-locking connection

126

material-locking connection

128

customization interface

130

supporting structure surface

132

adjustment section

134

foamed section

136

plastic material

138

adjustment element material

140

compact section

142

connection zone

144

square adjustment element

146

triangular adjustment element

148

pear-shaped adjustment element

150

extension plane

152

first customization interface

154

Paragraph

156

deepening

158

second customization interface

160

third customization interface

162

survey

164

group of adaptation elements

165

wall element

166

first group of adaptation elements

168

first adjustment element

170

second adjustment element

172

third adjustment element

174

fourth adjustment element

176

fifth adjustment element

178

sixth adjustment element

180

adjustment element connecting section

182

plastic element

184

continuous plastic material

186

first adaptation element group connection section

188

second adaptation element group connection section

190

second group of adaptation elements

192

first direction

194

intragroup distance

196

spacing

198

second direction

200

intragroup distance

202

spacing

204

angle

206

opening surface

208

opening inner wall

210

overhang area

212

third group of adaptation elements

214

first straight

216

second straight

218

third straight

220

overlay area

222

support strut

224

Tool

226

forming tool

228

injection molding tool

230

forming units

232

first forming unit

234

second forming unit

236

mold halves

238

feed channel

240

plastic melt

242

expansion elements

244

expansion device

246

expansion element carrier

248

guide element

250

guide

252

installation step

254

adjustment element precursor

256

expansion step

258

expansion phase

260

expansion space

262

opening step

264

removal element

266

feed zone

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited non-patent literature

• DIN ISO 48-4:2021-02 [0062, 0066]

Claims (14)

Method for producing a structural element composite (100), e.g. a plastic component (102), wherein the structural element composite (100) can preferably be flat and/or plate-shaped and/or lattice-shaped, wherein the structural element composite (100) can preferably be a structural element composite (100) described herein, e.g. a plastic component (102) described herein and/or a structural element composite (100) described herein that is flat and/or plate-shaped and/or lattice-shaped, the method comprising the following: - in an attachment step (252), an adaptation element precursor (254) is attached to a support structure element (104) in a tool (224), in particular a shaping tool (226), e.g. an injection molding tool (228), in a form-fitting, force-fitting and/or material-fitting manner, e.g. B. injected, and - in an expansion step (256), a volume of the adaptation element precursor (254) is increased in an expansion section (258) of the adaptation element precursor (254) and an adaptation element (108) of the structural element composite (100) is produced from the adaptation element precursor (254). procedure according to claim 1 , characterized in that the volume of the adaptation element precursor (254) in the expansion section (258) is increased to such an extent that a compression hardness of the adaptation element (108) produced is at least approximately 4 and/or at most approximately 100 kPa. procedure according to claim 1 or 2 , characterized in that the tool (224) has a movable expansion element (242), wherein in the expansion step (256) to increase the volume of the adaptation element precursor (254) a position of the expansion element (242) is changed such that an expansion space (260) reaching to the expansion section (258) is created. procedure according to claim 3 , characterized in that the volume of the adaptation element precursor (254) in the expansion section (258) of the adaptation element precursor (254) is increased by physical and/or chemical foaming in the expansion space (260). Method according to one of the Claims 1 until 4 , characterized in that the adaptation element precursor (254) is produced completely or partially, preferably completely, from a foamable plastic material. Method according to one of the Claims 3 until 5 , e.g. after claim 5 , characterized in that the production of the adaptation element (108) is accompanied by a foaming of the expansion section (258) in the expansion space (260). Method according to one of the Claims 1 until 6 , characterized in that the support structure element (104) is produced in a support structure shaping zone, e.g. support structure injection molding zone, preferably from a plastic mass, wherein it may be preferred if the support structure shaping zone is provided in the tool (224) and the attachment of the adaptation element precursor (254) in the tool (224) takes place after the support structure element (104) has been produced. procedure according to claim 7 , characterized in that the attachment of the adaptation element precursor (254) takes place before cooling the produced support structure element (104) to a temperature of less than 45 °C. procedure according to claim 7 or 8 , characterized in that the attachment of the adaptation element precursor (254) takes place after cooling of the produced support structure element (104) to a temperature of at most 85 °C. Method according to one of the Claims 1 until 9 , characterized in that the adaptation element precursor (254) belongs to an adaptation element precursor group, wherein a precursor group space is formed in the tool (224) on one side or on both sides of the support structure element (104), in particular on an adaptation side (114) of the support structure element (104) and/or on a rear side (116) of the support structure element (104), and the adaptation element precursor group is produced in the precursor group space or through the precursor group space, wherein it can be preferred if the adaptation element precursor group is produced from the foamable plastic material. procedure according to claim 10 , characterized in that the tool (224) has, for example, a movable release element, wherein in the tool (224) on one side or on both sides of the support structure element (104), in particular on an adaptation side (114) of the support structure element (104) and/or on a rear side (116) of the support structure element (104), the precursor group space is released by a movement of the release element into a release position and the adaptation element precursor group in the precursor group space or through the precursor group space. Method according to one of the Claims 5 until 11 , characterized in that the adaptation element precursor (254) belongs to an adaptation element precursor group, wherein the adaptation element precursor (254) is a first adaptation element precursor (254) and a second adaptation element precursor (254) belongs to the adaptation element precursor group, wherein the foamable plastic material is fed from a common feed zone and is passed on in a dividing, e.g. branching, manner to produce the adaptation element precursors (254) of the adaptation element precursor group. Structural element composite (100), e.g. plastic component (102), wherein the structural element composite (100) can preferably be flat and/or plate-shaped and/or grid-shaped, obtainable by a process according to one of the Claims 1 until 12 . Structural element composite (100), e.g. plastic component (102), wherein the structural element composite (100) can preferably be flat and/or plate-shaped and/or grid-shaped, wherein the structural element composite (100) comprises the following: - a support structure element (104), which can e.g. be a plastic support structure element (106), wherein the support structure element (104) can preferably be flat and/or plate-shaped and/or grid-shaped, and - an adaptation element (108) fixed to the support structure element (104), which can e.g. be a plastic adaptation element (110), wherein the support structure element (104) and the adaptation element (108) are connected to one another in a form-fitting, force-fitting and/or material-fitting manner.

Images