AT11396U1

AT11396U1 - Method for producing a composite or hybrid construction

Info

Publication number: AT11396U1
Application number: AT0803710U
Authority: AT
Inventors: Peter Dipl Ing Egger; Helmut Ing Naderhirn; Georg Dr Steinbichler; Herbert Dipl Ing Zeidlhofer
Original assignee: Engel Austria Gmbh
Priority date: 2009-05-27
Filing date: 2010-06-02
Publication date: 2010-10-15
Also published as: CN101898401A; DE102010019625A1; JP5705910B2; JP2013144463A; CN103358462B; JP5596413B2; CN103358462A; JP2010274653A; DE102010019625B4

Abstract

A method for producing a composite or hybrid construction (50) comprising at least one thermoplastic component, wherein an injection molding machine (1) with at least one insert (6, 6 ') is used.

Description

Austrian Patent Office AT 11 396 U1 2010-10-15

Description: The invention relates to a method for producing a composite or hybrid construction comprising at least one thermoplastic plastic component.

For the production of composite structures and composite materials but also for the production of hybrid constructions different methods are known in the prior art. In composite materials, different materials are joined by fabric or form-fitting, or a combination of both. Worth mentioning are, for example, fiber composites, in which fiber fabric or knitted fabric are mixed with plastic in order to obtain in the end a composite construction which has improved properties. Hybrid designs combine systems with different technologies. Very often these are plastic / metal hybrids that combine the advantages of plastic and metal.

From the prior art known methods for the production of composite or hybrid constructions are usually multi-stage, resulting in a high cost and labor.

Object of the present invention is therefore to provide a method of the type mentioned, in which the workload and consequently the cost is reduced. This object is achieved by a method of the type mentioned, which is characterized by the use of an injection molding machine with at least one insert.

The use of an injection molding machine with at least one insert makes it possible to combine several process steps on the injection molding machine, so that different process steps can be combined quickly in place.

In one embodiment, it can be provided that are sprayed using an injection molding machine with at least two inserts and at least three injection stations through the first and second injection station two moldings, which are directed to each other after rotation of the inserts and connected by the third injection station , The use of two inserts and three injection stations makes it possible not only to quickly produce the individual molded parts, but also to connect them together in an immediately subsequent step. It can be provided that in one of the injection stations an insert, preferably a functional element and / or a reinforcing structure, is pre-positioned. In the preferred case, it is then provided that the insert part, preferably a functional element and / or a reinforcing structure, is positioned after the turning of the inserts and before the joining of the two mold parts between the two mold parts.

From a procedural point of view, it is advantageous if new moldings are injected after turning the inserts and preferably simultaneously with the joining of the already molded parts, in the first and second injection station.

In another embodiment, it may be provided that using an injection molding machine with at least one insert and at least one injection station in a parting plane between the insert and another platen a reinforcing structure, such as a fiber fabric, fiber fabric, prepreg or combinations thereof, is inserted and over-injected after turning the insert in the injection station. It can further be provided that the reinforcing structure - is preformed in the injection molding machine - before over-molding. Furthermore, it can alternatively or additionally be provided that the reinforcing structure is preheated in the injection molding machine before the overmolding.

In a further embodiment of the invention can be provided that the reinforcing structure is over-injected either by using a further injection station or by turning the insert on both sides. In one embodiment, it can be provided that the insert is punched by merging the insert and a further platen and / or a punching tool in the injection molding machine. The punching operation can either be performed by a mold or a part of the mold or be made by an additionally provided punching tool. However, such a punching tool can also interact with a part of the molding tool so that punching tool and molding tool jointly perform the punching operation.

In a further embodiment, it can be provided that the reinforcing structure is placed on a foil backing in the injection molding machine.

In all embodiments, it can be provided that the injection molding machine has two parting planes and in one of the parting planes, a structural element is preferably deformed via water pressure and over-injected in the other parting plane with plastic.

In addition, it can be provided that the injection molding machine has at least one Wen-deplatte with two parting planes, each of the parting planes an extruder and a screw injection unit are assigned, so that the production of the composite and / or hybrid construction is carried out by direct compounding.

Furthermore, it can be provided that the injection molding machine has at least one rotary cube with four mutually offset by 90 ° stations. Two of the stations can be designed as injection stations and in one station can be fed by a handling device an insert. In a station can be provided that a station is designed as a removal station or ejection station. In a further embodiment, it can be provided that the production of the composite or hybrid construction takes place at least partially by in-situ polymerization of at least one monomer in a cavity of the injection molding machine, wherein pressure buildup in the cavity takes place by reducing the size of the cavity when the polymerization starts. Furthermore, it can be provided that the production of the composite or hybrid construction takes place at least partially by applying a lacquer layer. For example, PUR has proved to be advantageous as in-situ polymers and / or as coating layers to be applied.

The molded parts produced in the intermediate steps are preferably half-shells.

In general, it has proved to be advantageous if the reinforcing structure (53) is selected from the group fiber fabric. Fiber fabric, prepreg or combinations thereof. It is advantageously provided that the fibers of the fiber fabric and / or fiber fabric are selected from the group of glass fibers, basalt fibers, carbon fibers or mixtures thereof.

Further details and advantages of the invention will be explained with reference to the following figures and description of the figures.

1 shows an injection molding machine for carrying out the method according to the invention, [0020] FIGS. 2a and 2b show a variant embodiment for carrying out the method using two inserts and the resulting composite constructions or hybrid constructions, [0021] FIG. 3a and 3b show a variant embodiment for carrying out the method using a turning insert and with a preforming and the resulting composite and hybrid constructions, Fig. 4 shows a variant for carrying out the method using a turning plate, wherein a reinforcing structure is preheated FIG. 5 shows two method steps for carrying out the method using a turning plate and a punching tool, FIG

Austrian Patent Office AT 11 396 U1 2010-10-15 [0024] FIGS. 6a and 6b show two process steps of an embodiment variant for carrying out the invention

7a and 7b show a variant embodiment for carrying out the method using two inserts and a punching tool; FIGS. 8a and 8b show a variant embodiment for carrying out the method Method using a turning plate, wherein a Fluiddruckvorformung is provided, Figs. 9a and 9b, a variant embodiment for carrying out the inventive

10 shows a variant embodiment for carrying out the method using a rotary cube, [0029] FIGS. 11a and 11b show a last embodiment variant for carrying out the method according to the invention using a reversing plate and a feeding device of a monomer and the composite or hybrid constructions made therefrom.

In Fig. 1, an injection molding machine 1 is shown, which can be used for the inventive method. The injection molding machine 1 has a closing unit 2 and a plasticizing and injection unit 3 in a known manner. The closing unit 2 comprises a fixed platen 4, which is fixedly arranged on a frame 9. Furthermore, a movable platen 5 is provided, which is linearly movable along the columns 10 on a slide shoe 7 on a slide rail 31, for example, shown in Fig. 2a. The movement of the movable platen 5 is effected by a drive cylinder 16 with a piston-cylinder unit from and to the movable platen 4. For fixing the movable platen 5 in the desired position on the columns 10 locking mechanisms 14 are provided, the positive and / or frictional Fix the mold clamping plate 5 to the columns 10. Furthermore, a turning plate 6 is provided which is movable on a sliding block 8 linearly between the movable platen 5 and the fixed platen 4. The insert 6 is arranged on a sliding block 8 in a slide rail 31. Furthermore, a driving cylinder 16 comprising a piston-cylinder unit for linear movement along the columns 10 from and to the fixed platen 4 is provided. The insert 6 additionally has a rotary unit 61, such as a turntable, so that rotation along the axis of rotation a can take place. The mold mounting plates 4, 5 and the insert 6 are arranged on a frame 9. Furthermore, pressure pads 13 are provided for mounting the fixed platen 4. The closing unit 2 has the parting planes A and B.

The plasticizing and injection unit 3 is also constructed as known per se, so that will be discussed here only shortly thereafter. Plastic granules can be transported into the plasticizing cylinder 18 via a hopper 17, where a plasticizing screw is arranged, which plasticizes the plastic granules. Plasticized plastic can be injected into the mold 11 via a nozzle 23 and an injection movement. For the plasticization and the subsequent injection, a drive unit 24 is provided which, on the one hand, sets the plasticizing screw in rotational motion and, on the other hand, carries out a linear movement for injection. The drive 24 may, as known per se, be designed, for example, hydraulically. The plasticizing and injection unit 3 is arranged on a frame 19. On the movable platen 5, a further plasticizing and injection unit 20 is provided. This is arranged on a frame 22 which is connected to the fixed platen 4. Upon movement of the movable platen 5 from or to the fixed platen 4, the injection unit 20 makes this movement with. The injection unit 20 also has a hopper 21 for plastic granules and a plasticizing unit 25, which also forms an injection unit at the same time. Via a nozzle 26 can be injected into the mold 3/19 Austrian Patent Office AT 11 396 U1 2010-10-15 12 plasticized plastic.

In the embodiment shown, two molds 11,12 can be seen, each of two mold halves 11 ', 11 " or 12 ', 12 " be formed. Due to the relative movement of movable platen 5, turning plate 6 along the columns 10 towards the fixed platen 4 (or away from it), the respective tool halves 11 ', 11 " or 12 ', 12 " and form the molding space for the thermoplastic resin component injected in the plasticized state. In this case, it is first possible to inject into the first closed mold 11, and then, after opening the mold 12, to turn the insert 6 around the axis of rotation a by 180 ° so that the mold half 11 " in the image plane now comes to rest on the position of the former mold half 12 '. By closing the mold, the mold halves 11 " and 12 " into one another and form a new mold, it being understood that the molding formed in the first cycle is molded on the mold half 11 " is arranged and introduced into the new mold. Then, via the injection unit 20, a further thermoplastic component can be injected and the finished composite or hybrid construction 50 can be formed. Furthermore, an insert may be introduced into one of the two molds 11, 12 before one of the two injection processes. Of course, in the molds 11 and 12 are also injected simultaneously. It is thus provided that 6 molded parts are simultaneously molded after turning the insert. The plasticizing and injection unit 3 and the mold 11 form an injection station and the plasticizing and injection unit 20 with the mold 12 form a further injection station.

In Fig. 2a, a variant is shown, which corresponds substantially to the example of FIG. 1, except that now on the closing side 2 in addition to the fixed platen 4 and the movable platen 5, a first insert 6 and a second insert 6th 'Are arranged linearly movable on the slide 31. In this embodiment, three parting planes A, B, C are provided. In addition, a third plasticizing and injection unit 30 is provided which is arranged approximately L-shaped to the first plasticizing and injection unit or to the second plasticizing and injection unit 20. The plasticizing and injection unit 30 is arranged on the insert 6 and makes their movements with. For the sake of clarity, the marking of the remaining components on the closing unit 2 as well as on the plasticizing and injection units 3, 20 and 30 has been dispensed with.

It should be noted that the reference numerals in all figures match, so it is omitted to explain each reference number again for each figure. Reference is made to the respective preceding description of the figures.

In a first method step, the individual platens 4, 5 and inserts 6, 6 'are moved relative to one another such that the forming tools 11, 12, 121 (formed by the mold halves 11', 11 ", 12 ', 12", 121) ', 121 ") and form the respective desired shape. On the side of the mold 11 plasticized thermoplastic component is injected via the plasticizing and injection unit 3, so that subsequently the molded part 51 in the form of a half-shell (see Fig. 2b) is formed. At the same time, the molding 52 can be formed on the molding tool 12 via the injection unit 20. After the shaping of the mold parts 51, 52, the individual molds 11, 12, 121 are opened by moving apart of the individual mold plates 5, 6, 6 ', wherein the mold part 51 is pressed onto the mold half 11 " and the molding 52 on the mold half 12 " remains. Subsequently, the turning plates 6, 6 'are rotated through 180 ° along their axes of rotation a, b, so that in the region of the center the mold halves 12' and 11 " are directed towards each other. About a handling device 60, an insert 53 can be inserted into the newly emerging form. Subsequently, the individual molds are closed again and an injection unit 6 fixedly arranged on the injection unit 30 via the line 31 plastic in the new shape, formed from the mold halves 11 " and 12 ', injected so that the mold parts 51, 52 are connected to each other. The insert 53 is simultaneously connected to the mold parts 51, 52. As insert 53 in the case shown, a functional element, such as an antenna (but also a transponder, RFID, etc.) is conceivable. By opening the molds, the finished composite or hybrid constructions 50 can be seen.

In FIG. 3a, the mold 12 forms a preforming unit at the same time, the insertion part 53, which is inserted with a handling device 60, is preformed by the applied pressure and optionally temperature increase to the preform 56. After opening the molds, turning the insert 6 about the axis of rotation a, the preform remaining in the mold half 12 'can be inserted into the newly formed mold and then molded with thermoplastic plastic component from the plasticizing and injection unit 3.

4 shows now a variant with only one insert 6 and only one plasticizing and injection unit 3. In the open state, an insert 53 is placed in the mold 12 on the mold half 12 " placed. The molding tool 12 has a heating device 70, which heats the insert 53 in advance. The insert 53 is in the preferred case a so-called prepreg (sometimes referred to as organo sheet). In the preferred case, this is a fiber-reinforced plastic, for example glass-fiber-reinforced thermoplastic. The insert 53 thus forms a reinforcing structure. In the specific case, the insert 53 is a prepreg with glass-fiber reinforced plastic, which is inserted into the mold 12 and heated by the heating device 70, so that the plastic softens. The heating takes place in the closed mold 12. After heating and an optional embossing within the mold 12, the mold 12 is opened again, the insert 6 rotated, the insert 53 in the heated state on the mold half 12 'and when closing with the mold half 11th 'forms a new mold. Subsequently, via the injection and plasticizing unit 3, plasticized plastic can be formed into the mold, injected through the mold halves 11 ', 12', and a corresponding composite or hybrid construction 50 can be produced.

5, a further embodiment is shown, in which an insert 53 is introduced, in which a material web 53 'by means of a punch 71, which at a projection 72 of the mold half 12 " engages so that a part of the material web 53 'is punched out. The punching tool 71 is moved over the mold half 12 " until it rests against the stop of the projection. The insert 53 is thereby separated from the web of material 53 'and transferred into the mold 12'. After opening the mold, the insert 6 is rotated, transferred to the right position of the image plane and enclosed by closing the mold by engagement of the mold halves 12 'and 11' in the resulting mold. Finally, thermoplastic plastic component is injected into this mold via the plasticizing and injection unit 3 and the finished composite or hybrid construction 50 is produced.

6a and 6b show a very similar to the embodiment of FIG. 4 variant, in turn, an insert 53 is inserted via a handling tool 60 in the mold 12. This can be molded from one side via the plasticizing and injection unit 30, which is arranged on the insert 6, with thermoplastic component. This is shown in FIG. 6b. After opening the mold 12, turning the insert 6 and closing again, the second side of the molding 51 can be injection-molded via the plasticizing and injection unit 3. The produced composite or hybrid construction 50 is shown in the lower right-hand illustration, wherein two outer plastic layers 51, 52 and an insert layer 53 lying therebetween can be seen. Again, the insert may be a prepreg or other materials.

Fig. 7a shows a combination of the embodiments of Figs. 5 and 6a and 6b, wherein first of a web of material 53 'an insert 53 is punched with a punching tool 71 and is introduced into the first mold 12. After turning the first turning plate 6 ', one side of the insert 53 can be injection-molded via the plasticizing and injection unit 30. After reopening the mold, turning the insert 6 and closing the mold, the second side of the insert 53 can be overmolded by the plasticizing and injection unit 3.

FIGS. 8a and 8b show a further embodiment variant for carrying out the method. In this case, an insert 53 is introduced into a first mold via a handling device 60. 5/19 Austrian Patent Office AT 11 396 U1 2010-10-15 About so-called hydroforming in the form can be generated from the insert 53 via a fluid on the left in Fig. 8b shape shown. After turning the insert 6, re-closing and injecting via the plasticizing and injection unit 3, the finished composite or hybrid construction 50 can be produced according to the right-hand illustration of FIG. 8b.

In FIGS. 9a and 9b, a variant of the invention is shown in which, in addition to the plasticizing and injection unit 3 and the plasticizing and injection unit 20, twin-screw extruding units 99, 99 'are additionally provided. These serve to enable direct compounding. In this case, the plasticizing and injection unit 3 is used to plastically plasticize a thermoplastic plastic component and / or additionally to plasticize it via the twin-screw extruder 99 with a further thermoplastic plastic component with additional components. This is conveyed into the plasticizing cylinder of the injection unit 3, which performs an injection process after closing the mold 11. The same applies to the injection unit 20 and its associated twin-screw extruder system 99 '. The production of composite or. Hybrid construction 50 (possibly also with insert 53) takes place analogously to the description of FIG. 1. In addition, a shot pot (not shown) may be provided so that twin-screw extruder 99, 99 'can also plasticize during injection through injection unit 3, 20.

In Fig. 10, a variant is shown, with a rotary cube 6, in which the axis of rotation a horizontal, that is normal to the plane of representation, wherein the rotary cube 6 has four positions or stations I, II, III, IV, the separated by 90 °. But just as well can be provided that the rotation axis a is arranged vertically as in the previous examples. For reasons of clarity, however, the representation shown in FIG. 10 has been selected, since in this way the individual stations I, II, III, IV can be better seen. The first station I describes an injection molding process for a first molded part in the form of a half shell. After opening the mold, the insert is rotated 90 ° and a handling device 60 an insert 53 in the mold half 11 'brought (station II). After another 90 ° turn (station III), the mold is closed again and thermoplastic components are injected via the plasticizing and injection unit 20. After reopening the mold and rotating the insert or rotation cube by 90 °, the finished composite or hybrid construction can be removed via a removal station (Station IV). This is a ejection station.

The embodiment variants of FIGS. 11a and 11b differ from the exemplary embodiment of FIG. 1 only in that, in addition to the plasticizing and injection unit 20, there is additionally provided a unit 93 for the insertion of polymer material still to be polymerized. In this case, at least one monomer is introduced into the cavity and polymerized in the cavity. At the start of the polymerization, an increased pressure in the cavity is built up by reducing the size of the cavity. Here, for example, a thin paint layer 52 z. B. a PUR paint can be applied. Alternatively, thermoplastic plastic component can also be introduced via the plasticizing and injection unit 20. Preferably, the thermoplastic resin component is applied as a thin layer, for example by injection-compression molding.

In the embodiments with the exception of Fig. 10 it can be provided that the axis of rotation (s) a, b of the insert (s) 6, 6 'is not perpendicular but also horizontal (as in Fig. 10) is arranged (are ). 19.6

Claims

Austrian Patent Office AT 11 396 U1 2010-10-15 Claims 1. A method for producing a composite or hybrid construction (50) comprising at least one thermoplastic plastic component, characterized by the use of an injection molding machine (1) with at least one insert (6, 6 ') ,
2. The method according to claim 1, characterized in that using an injection molding machine (1) with at least two inserts (6, 6 ') and at least three injection stations through the first and second injection station two mold parts (51, 52) are injected, which after a rotation of the inserts (6, 6 ') to each other and are connected by the third injection station.
3. The method according to claim 2, characterized in that in one of the injection stations, an insert part (53), preferably a functional element and / or a reinforcing structure, is pre-positioned.
4. The method according to claim 3, characterized in that the insert part (53), preferably functional element and / or reinforcing structure, after turning the inserts (6, 6 ') and before connecting the two mold parts (51, 52) between the two Shaped parts (51,52) is positioned.
5. The method according to claim 2 or 3, characterized in that after turning the inserts (6, 6 ') and preferably simultaneously with the joining of the already molded parts (51, 52), in the first and second injection station new moldings (51 , 52) are sprayed.
6. The method according to any one of claims 1 to 5, characterized in that using an injection molding machine (1) with at least one insert (6, 6 ') and at least one injection station in a parting plane (A, B. C) between the insert ( 6, 6 ') and a further platen (4, 5) a reinforcing structure (53), such as a fiber fabric. Fiber fabric, prepreg or combinations thereof, inserted and over-molded after turning the insert (6, 6 ') in the injection station.
7. The method according to claim 6, characterized in that the reinforcing structure (53) - is preformed in the injection molding machine - before over-molding.
8. The method according to claim 6 or 7, characterized in that the reinforcing structure (53) - is pre-heated in the injection molding machine (1) - before over-molding.
9. The method according to any one of claims 1 to 8, characterized in that the reinforcing structure (53) either by using a further injection station or by turning the insert (6, 6 ') is over-injected on both sides.
10. The method according to any one of claims 2 to 9, characterized in that the insert (53), preferably a reinforcing structure, by merging the insert (6, 6 ') and a further platen (4, 5) and / or a punching tool ( 71) in the injection molding machine (1) is punched.
11. The method according to any one of claims 3 to 10, characterized in that a reinforcing structure (53) on a foil backing in the injection molding machine (1) is introduced.
12. The method according to any one of claims 1 to 11, characterized in that the injection molding machine (1) has two parting planes (A, B, C) and in one of the parting planes (A, B, C), a structural element (53), preferably via Fluid pressure such as water pressure, deformed and in the other parting plane (A, B, C) is over-injected with plastic. 7/19 Austrian Patent Office AT 11 396 U1 2010-10-15
13. The method according to any one of claims 1 to 12, characterized in that the injection molding machine (1) at least one insert (6, 6 ') having two parting planes (A, B, C), each of the parting planes (A, B, C) an extruder (99, 99 ') and a screw injection unit are assigned, so that the production of the composite or hybrid construction (50) takes place by direct compounding.
14. The method according to any one of claims 1 to 13, characterized in that the injection molding machine (1) at least one rotary cube (6) with four mutually offset by 90 ° stations (I, II, III, IV).
15. The method according to claim 14, characterized in that two of the stations (I, II, III, IV) are designed as injection stations.
16. The method according to claim 14 or 15, characterized in that in a station by a handling device (60) an insert part (53) can be fed.
17. The method according to any one of claims 14 to 16, characterized in that a station is designed as a removal station or ejection station.
18. The method according to any one of claims 3 to 17, characterized in that the reinforcing structure (53) is selected from the group fiber fabric, fiber fabric, prepreg or combinations thereof.
19. The method according to claim 18, characterized in that the fibers of the fiber fabric and / or fiber fabric are selected from the group of glass fibers, basalt fibers, carbon fibers, natural fibers or mixtures thereof.
20. The method according to any one of claims 1 to 19, characterized in that the production of the composite or hybrid construction (50) at least partially by in situ polymerization of at least one monomer in a cavity of the injection molding machine (1), wherein at the start of the Polymerization pressure build-up in the cavity by reducing the cavity takes place.
21. The method according to any one of claims 1 to 20, characterized in that the production of the composite or hybrid construction (50) takes place at least partially by applying a lacquer layer.
22. The method according to claim 20 or 21, characterized in that the in situ polymer or the paint layer comprises PUR. For this 11-sheet drawings 8/19