Fundamental investigation of cutting, forming and assembly injection moulding and their interdependence for manufacturing durable tight electronic systems

该项目的总体目标是在短工艺链中制造用于电子应用的介质密封塑料金属混合体，同时考虑到金属和塑料加工各个工艺的相互依赖性。基于第一阶段的研究结果，可以得出新的基础研究方面，可以用已建立的测试设备进行分析。由于观察到封装过程中带有压花凹槽的金属插入件的明显变形，因此将研究通过多阶段压花工艺控制材料流动和材料分布的可能性和限制。目的是在保持嵌件整体性的同时提高嵌件的刚度，实现高精度的模压结构成形，并进一步研究二次表面结构的影响和制造方法。这些二级结构将被应用，以增加金属插入件的某些区域中的结合强度。这种分层表面结构可以通过另外结构化的压印工具（例如，G.通过喷砂或µEDM）或蚀刻技术。此外，迷宫式密封或延长密封路径的效果以及界面粘结强度的增加将被结合起来，并使用预热插件进行检查。该项目的第二阶段重点关注聚合物金属混合物特性的差异化分析，即材料和几何形状之间的相互作用对环境应力的响应。以往的研究表明，如果选择理想的工艺参数，不同品种的试样在注射成型后不久就具有相似的紧密性。然而，预计不同处理的工件之间将出现显著差异，以增加应力和老化。在此基础上，研究塑料金属混合部件的长期行为，其性能曲线和故障机制的识别也是该项目的目标。特别是，发生的热机械应力作为蠕变和松弛的结果作为填料系统的功能下的气候和机械应力将进行调查。最后，两个项目阶段的研究结果将统一在一个多学科的，有限元为基础的方法负载适应设计的塑料金属混合部件。

The overall objective of the project is manufacturing media-tight plastic metal hybrids for electronic applications in a short process chain, taking into account the interdependence of the individual processes for metal and plastic processing. Based on the findings of the first project phase new fundamental research aspects can be derived which can be analyzed with the established testing facilities.Since a distinct deformation of metal inserts with embossed grooves during encapsulation was observed, the possibilities and limits of controlling material flow and material distribution by a multi-stage embossing process will be studied. The objective is to improve the rigidity of the insert while preserving its integrity and to achhieve a high forming accuracy of the embossed structures.Furthermore, the influence and the manufacturing of secondary surface structures will be studied. Those secondary structures will be applied in order to increase the bond strength in certain areas of the metal inserts. Such a hierarchical surface structure can be created by additionally structured embossing tools (e. g. by blasting or by µEDM) or etching technology. Furthermore the effect of a labyrinth seal or an extended sealing path with an increase in the bond strength of the interfaces will be combined and examined using pre-heated inserts.The second phase of the project focuses on the differentiated analysis of the characteristics of the polymer metal hybrids in regard to interactions between material and geometry in response to environmental stress. Previous investigations proved that different varieties of specimens are similarly tight shortly after the injection molding if ideal process parameters were chosen. However it is expected that significant differences between the differently treated workpieces will occur for increasing stressing and aging. Based on this information, the study of the long-term behavior of the plastic metal hybrid components, their property profile and the identification of failure mechanisms is also object of the project. In particular, the occurrence of thermo-mechanical stresses as a result of creep and relaxation as a function of the filler system under climatic and mechanical stress will be investigated. Conclusively, the findings of the two project phases will be united in a multidisciplinary, FE based methodology for load-adapted design of plastic metal hybrid components.