CN107263796B - 热固性模制品的制造方法 - Google Patents

热固性模制品的制造方法 Download PDF

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CN107263796B
CN107263796B CN201710218428.7A CN201710218428A CN107263796B CN 107263796 B CN107263796 B CN 107263796B CN 201710218428 A CN201710218428 A CN 201710218428A CN 107263796 B CN107263796 B CN 107263796B
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CN107263796A (zh
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丹尼尔·奥斯特纳
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Lisa Draexlmaier GmbH
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Abstract

本发明涉及一种具有纤维强化支撑件和至少一个装接部件的模制品的简化的制造方法，所述至少一个装接部件与所述纤维强化支撑件连接并且由塑料制成，其中，模制品特别适于用作或者再加工为诸如机动车辆、轮船和或飞机这样的所有种类的运输工具的内部空间中的装饰部件。

Description

热固性模制品的制造方法
技术领域
本发明涉及一种具有纤维强化支撑件和至少一个装接部件的模制品的简化的制造方法，所述至少一个装接部件与所述纤维强化支撑件连接并且由塑料制成，其中，模制品特别适于用作或再加工为诸如机动车辆、轮船和/或飞机这样的所有种类的运输工具的内部空间中的装饰部件。
背景技术
从背景技术中已知用于装饰部件，例如用于车门内衬、门中央面板、中控台和仪表板等的支撑件，其通过注塑成型或通过按压热塑性/热固性天然纤维垫系统而制造。
如此制造的支撑件的与例如加强肋、紧固件等这样的功能元件(塑料部件)的连接通常通过将塑料部件粘合或焊接于支撑件材料来实现。
接着，利用装饰物覆盖所述支撑件。
一种可选的制造方法是装饰物的直接后注塑。
在支撑件被压制的情况下，通常在不同的工序中使用不同的工具执行压制支撑垫和注塑功能元件以及将功能元件连接到被压制的支撑件的工序。
德国专利申请DE 10 2004 054 228 A1公开了一种用于制造模制品的方法和设备，其中，在第一步骤中，加热含有天然纤维的例如垫的形式的坯料，然后，通过将两个模制元件压在一起生产该坯料制成的模制品，并且然后，在另一步骤中，通过将塑料熔化物注塑在模制品上而模制功能部件，其中，在注塑所述塑料熔化物之前，在模制品中形成空腔。这些步骤全部在一个设备中执行。
在德国专利DE 692 22 130 T2中公开了类似的方法和类似的设备。
在上述两种情况下，所述功能元件或塑料部件被注塑到所述天然纤维垫上。然而被按压的垫与功能部件的改进的一体化要求进一步的加工步骤，必要时要求使用额外的设备。
德国专利公开DE 10 2011 005 350 A1提出了一种天然纤维垫与功能元件之间的改进的一体化，其涉及的所使用的设备能够被视为本文描述的技术改进方案的起点。DE 102011 005 350 A1中公开的设备具有两个能够相互移动的工具构件。在工具构件打开的状态下，能够插入纤维强化垫，而在闭合时利用压力压制并且加固该纤维强化垫。两个工具构件中的一个工具构件设置有喷嘴，液态的塑料通过该喷嘴施加到插入的垫上，使得塑料熔化物渗透过插入的垫并且到达相反侧的、在另一个工具构件中形成的空腔中。
然而，这种方法已经被证明为是不利的，因为其必须在不同温度下在一侧上进行纤维强化垫的成型步骤，并且在另一侧上施加塑料熔化物以形成装接部件，这使得整个工艺更加复杂并且从而是费时的。
从更有效率地生产这种模制品的方面出发，目的是提供一种改善的方法，使得能够简化模制品的制造过程并且缩短制造时间。
发明内容
从而本发明的主要目的在于，简化用于制造模制品而进行的将压制的、纤维强化的支撑件与具有塑料的装接部件的一体化，特别是在简单的温度控制下实现一个以上的装接部件在支撑件上的形成。
利用权利要求1的特征的方法实现该目的。此外，本发明涉及根据权利要求9所述的根据本发明制造的模制品作为复合材料半成品的用途，以及根据权利要求10的包含这些复合材料半成品的车辆。其它实施方式是相应的从属权利要求的主题。
从现有技术中已知执行根据本发明的方法的设备。德国专利申请DE 10 2011 005350 A1公开了用于制造一种模制品的设备和方法，该模制品具有纤维强化支撑件以及至少一个与之相连接的具有塑料的装接部件。在图1A和图1B中示意性地示出这样的设备。
附图说明
图1A和1B给出了背景技术已知的适用于执行根据本发明的方法的工具。
具体实施方式
其中设备具有至少两个工具构件10、20，这两个工具构件中的至少一个工具构件10能够相对于另一个工具构件20移动，并且设备以这种方式打开以插入纤维强化垫30，并且该设备能够闭合以对所述垫30施加压力并且挤压该垫30。在压制之后，首先获得了期望的纤维强化支撑件。
此外，至少一个工具构件20具有至少一个喷嘴22用以供应液化塑料。另一个工具构件10具有用于形成装接部件的空腔12。在制造纤维强化支撑件之后，通过使得液化塑料通过喷嘴22并且经过垫30而引入空腔12并且凝固在空腔内，能够由此制造装接部件并且将装接部件一体化在支撑件中。
这样的制造方法的缺点在于，根据现有技术的已知方法的垫的热固性成型步骤依据使用的材料而在大约140℃至200℃的温度下进行，而注塑成型的步骤需要在大约20至80℃的温度区间中进行，这要求遵循一定时间间隔以将工具冷却到上述较低的温度水平。
从更有效率的生产这种模制品的方面出发，本发明所基于的目的是提供一种方法，使得能够简化模制品的制造过程并且缩短制造时间。
根据本发明，通过用于形成纤维强化支撑件的低温热模压与工程塑料的注塑成型工艺的组合来实现该目的。
适合用于制造支撑件的是能够在100℃-140℃的低温范围内变形的聚合物，优选为热固性塑料。特别优选地，所谓的丙烯酸酯树脂、酚醛树脂或环氧树脂是适于制造支撑件的，它们的反应温度能够通过合适的活化剂降低。各种丙烯酸酯树脂以商品名
Figure BDA0001262999060000041
而能够商购。如有必要，也可以使用所谓的共混聚合物。
工程塑料适用于同时进行的注塑成型工艺，该工程塑料适于在上述温度区间内进行处理。从现有技术中已知大量这样的工程聚合物，例如，聚酰胺(PA)、聚对苯二甲酸乙二酯(PET)、聚对苯二甲酸丁二酯(PBT)、聚甲醛(POM)和/或聚碳酸酯(PC)，其中聚对苯二甲酸丁二酯(PBT)、聚碳酸酯(PC)和聚酰胺(PA)是优选的。必要时还可以使用合适的共聚物和/或共混聚合物。
上述塑料在制造期间能够添加所谓的添加剂，该添加剂用于精确调整材料特性以满足根据本发明的方法的需求。
从而，塑料可以具有例如邻苯二甲酸酯这样的软化剂，其影响塑料的脆性、硬度和玻璃化转变温度，从而使其更适合成型和加工。此外，可以使用也能够改善可加工性的例如环氧化油、高沸点矿物油和石蜡这样的所谓的延伸剂(二次增塑剂)。
另外，使用的塑料可以具有稳定剂，该稳定剂用于改善化学性能，并且使塑料免受诸如氧化、(UV或热)辐射这样的破坏性影响，从而延长其寿命。
此外，特别是当制造的模制品要在航空中使用时，塑料应具有阻燃剂，例如多溴二苯醚(PBDE)、氢氧化铝(Al(OH)3)(ATH)或含磷化合物。
最终，根据预期用途，塑料可以具有填料、强化材料或颜料。
在本发明的方法的示例性实施方式中，纤维强化垫30被置于处于打开状态的两个工具构件10、20之间，其中，一个工具构件20具有至少一个用于供应液化塑料的喷嘴22，并且另一个工具构件10具有至少一个用于形成装接部件的空腔12。
为了制造纤维强化支撑件，通过闭合工具构件10、20，对所述垫30施加压力并且挤压该垫30，其中，将塑料同时通过喷嘴22穿过垫30引入至空腔12中用以形成装接部件。
在冷却之后，可以将由纤维强化支撑件以及与其连接在一起的装接部件构成的固化的模制品从工具取出。
根据本发明的方法，工具构件10、20具有从90℃至150℃的区间的工具温度，优选的是从105℃至125℃的区间，尤其优选的是从105℃至115℃的区间，并且最优为110℃。
纤维强化支撑件或垫包括低温树脂系，其优选地实施为丙烯酸酯树脂、环氧树脂或聚糠醇。从现有技术中已知其它的低温树脂系。
此外在另一优选的实施方式中，低温树脂系可以含有活化剂，该活化剂例如通过较弱的交联而降低对于固化树脂的形成所需的反应温度。
纤维强化支撑件可以含有合成纤维和/或天然纤维。现有技术中已知大量的合成纤维。可以提及的实例是聚酰胺纤维、聚酯纤维、聚烯烃纤维、聚氯乙烯纤维、聚丙烯腈纤维、聚醚砜纤维、聚乙烯醇纤维、聚偏二氟乙烯纤维、聚四氟乙烯纤维和聚氨酯纤维，其中由聚醚砜(PES)或聚丙烯腈(PAN)制成的高强度合成纤维和标准合成纤维是优选的。
天然纤维可以是有机的(植物或动物)，或者是无机来源(矿物)。作为天然纤维的材料，已有洋麻，亚麻，黄麻，大麻，剑麻，竹，椰子，蕉麻，海草和/或木纤维。合适的矿物纤维例如是玻璃纤维、玄武岩纤维和/或碳纤维。这些纤维提供很轻的、坚固的纤维复合材料，并且也能够更好的且以低成本的方式获得。
根据本发明，用于形成装接部件而使用的塑料是工程塑料，优选是聚酰胺(PA)或聚丁烯对苯二甲酸酯(PBT)。
此外，本发明涉及根据本发明制造的模制品的作为复合材料半成品的用途。优选地，如此制造的复合材料半成品用于车辆制造业，并且特别用在机动车辆制造业或飞机制造业中。
此外，本发明涉及一种车辆部件，其含有根据本发明制造的复合材料半成品，其中，该车辆部件是车辆内部装饰件的组件。

Claims (13)

1.一种用于制造模制品的方法，该模制品具有纤维强化支撑件以及至少一个与该纤维强化支撑件连接的塑料的装接部件，所述纤维强化支撑件含有合成纤维和/或天然纤维，所述方法包括步骤：
a)将纤维强化垫(30)置于处于打开状态的两个工具构件(10、20)之间，其中，一个工具构件(20)具有至少一个用于供应液化塑料的喷嘴(22)，并且另一个工具构件(10)具有至少一个用于形成装接部件的空腔(12)；
b)为了制造纤维强化支撑件，将所述工具构件(10、20)闭合，从而对所述垫(30)施加压力并且挤压该垫(30)，其中，将塑料同时通过所述喷嘴(22)和穿过所述垫(30)引入至所述空腔(12)中，用以形成装接部件，
c)冷却并且取出具有纤维强化支撑件以及与该纤维强化支撑件相连的装接部件的固化的模制品，
其特征在于，所述垫具有低温树脂系，并且所述低温树脂系含有活化剂，该活化剂降低了低温树脂系所需的反应温度，并且至少在压制所述垫期间，所述工具构件(10、20)具有90℃至150℃区间的工具温度。
2.根据权利要求1所述的方法，其特征在于，所述的低温树脂系为丙烯酸酯树脂、环氧树脂或聚糠醇。
3.根据权利要求1所述的方法，其特征在于，所述工具构件(10、20)至少在压制所述垫期间具有从105℃至125℃区间的工具温度。
4.根据权利要求3所述的方法，其特征在于，所述工具构件(10、20)至少在压制所述垫期间具有从105℃至115℃区间的工具温度。
5.根据权利要求4所述的方法，其特征在于，所述工具构件(10、20)至少在压制所述垫期间具有110℃的工具温度。
6.根据权利要求1所述的方法，其特征在于，所述合成纤维从包含高强度合成纤维和聚酯类制成的标准合成纤维或聚丙烯腈制成的合成纤维组成的组群按比例地选择。
7.根据前述权利要求的任意一项所述的方法，其特征在于，所述支撑件包含混合羊毛或层压板。
8.根据前述权利要求1所述的方法，其特征在于，为形成所述装接部件而提供的塑料是工程塑料。
9.根据权利要求8所述的方法，其特征在于，所述工程塑料是聚酰胺、聚对苯二甲酸乙二酯、聚对苯二甲酸丁二酯、聚甲醛、聚乙烯和/或聚碳酸酯。
10.根据权利要求9所述的方法，其特征在于，所述工程塑料是为聚酰胺和/或聚对苯二甲酸丁二酯。
11.一种根据前述权利要求1至10之一所述的方法制造的模制品的用作复合材料半成品的用途。
12.一种车辆部件，该车辆部件包含根据权利要求1至10之一所述的方法制造的模制品。
13.根据权利要求12所述的车辆部件，其特征在于，所述车辆部件是车辆内部装饰的一部分。
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