CN110382197A - 用于制造纤维增强塑料成型件的方法和设备 - Google Patents

用于制造纤维增强塑料成型件的方法和设备 Download PDF

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CN110382197A
CN110382197A CN201880010653.4A CN201880010653A CN110382197A CN 110382197 A CN110382197 A CN 110382197A CN 201880010653 A CN201880010653 A CN 201880010653A CN 110382197 A CN110382197 A CN 110382197A
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M·沙德豪泽
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Abstract

本发明描述一种用于制造纤维增强塑料成型件的方法和设备，其中，使用经覆层的纤维条。为了对纤维条(2a)覆层，首先由经电离的空气产生空气流并且将其引导通过文丘里喷嘴(9)。将粉末(11)借助螺杆输送机(13)从储备容器(12)取出并且输送给文丘里喷嘴(9)，沿流动方向在文丘里喷嘴(9)下游存在或形成由粉末空气混合物构成的流。将所述流引入到腔室(4)中，将接地的或与粉末相反电离的纤维条(2a)移动穿过该腔室(4)且穿过流动通过腔室(4)的粉末空气混合物，粉末颗粒沉积到纤维条(2a)上。因此，从腔室(4)导出的纤维条(2b)具有覆层，将这样覆层的纤维条(2b)输送给注塑成型机(1)或挤出机(1)的塑化装置。

Description

用于制造纤维增强塑料成型件的方法和设备
为了制造纤维增强的塑料产品，已知将连续的纤维条在塑化装置中混入到熔化的塑料材料中并且将这样混合的材料输送给成型装置。所述成型装置可以是注塑工具或挤出工具。根据成型装置，所述塑化装置可以设计成不同的。在注塑工具的情况下，塑化装置例如可以设计成具有不能轴向移动的螺杆的双螺杆挤出机，并且所述材料可以借助连接于下游的注射单元被引入到注塑工具中。同样也已知螺杆预塑化装置设置有唯一的螺杆并且将材料借助连接于下游的注射单元引入到注塑工具中。在此，螺杆在螺杆预塑化装置的情况下可以是轴向位置固定的螺杆或者也可以构造成往复式螺杆。在最后提到的情况中，不仅设置有旋转驱动装置也设置有线性驱动装置。在注塑工具的情况下，塑化装置也可以仅构造有一个往复式螺杆，也就是说塑化和注塑成型利用一个且同一个螺杆进行。在挤出工具的情况下，塑化装置可以设计成单螺杆挤出机或多螺杆挤出机(例如双螺杆挤出机)。由前述类型已知的塑化装置例如在EP1144174B1、EP1306187B1和DE423662C2中公开。
由US5094883已知，粉末材料被施加到纤维条上。首先将待覆层的纤维条接地并且然后引导穿过如下壳体，这些纤维条在所述壳体中遭受粉末空气混合物。为了产生粉末空气混合物，使用所谓的流化床法。在壳体中设置有多孔隙板，该板可以被置于振动。在所述板上铺设确定量的粉末并且在那里形成粉末储备。在多孔隙板的下方，所述壳体衔接到通道上，经干燥的空气可通过所述通道从下面被引入到所述壳体中。在多孔隙板的下方设置有电离器，流入的空气可以借助该电离器被电离。电离的空气被引导通过多孔隙板以及通过所述粉末。在此，粉末从多孔隙板上被抬起并且与电离的空气一起在多孔隙板上方一定间距处形成粉末空气混合物。如果纤维条被移动通过所述粉末空气混合物，则粉末沉积在纤维条上。纤维条随后被移动通过炉子，以便熔化粉末并且实现粉末与纤维条的好的附着。这样覆层的纤维条最后被输送给辊，在那里纤维条被卷绕并且最终形成经覆层的纤维材料的储备。
由DE102014213320A1已知，借助喷枪用粉末对工件覆层(第[0019]段)。在此，在储备容器中产生粉末空气混合物，其表现得像液体。也可以说，粉末在储备容器中“流化”。所述流化的粉末随后通过软管或管流至涂覆装置(例如具有相应喷嘴的喷枪)。为了给粉末颗粒充电，设置有喷射电极。被充电的粉末借助喷枪被喷射并且保持附着在接地的工件上。根据DE1020142113320A1，待覆层的工件可以是基本上例如至少50重量％、优选至少75重量％或仅由碳纤维构成的工件。术语“碳纤维”包括单个纤维或丝线，但也包括由其构成的成圈针织物、编织物、拉圈针织物、纺织物、非织造网布或类似物。
在已知的粉末覆层法中，虽然粉末可以相对均匀地被施加到纤维条上。然而不利的是，每单位量的纤维条(例如每千克纤维条)的层厚或粉末含量不能被调节或至少不能足够精确地被调节。这在将这样覆层的纤维材料直接加工成由塑料熔体和纤维材料构成的混合物时会产生不利影响。更确切地说，不能在所加入的纤维条上制造具有限定份额层材料的成型件。
由此出发，本发明的任务在于，给出一种用于制造纤维增强塑料成型件的方法和设备，其中，所述塑料成型件被掺入纤维，该纤维具有限定份额的覆层材料。
所述任务的解决方案通过一种具有权利要求1特征的方法和一种具有权利要求5特征的设备实现。有利的设计方案和扩展方案在从属权利要求中给出。
本发明的核心构思可被认为在于，纤维条被均匀地覆层有每单位时间或每单位纤维长度规定量的粉末。为此，按照本发明设置，为了对纤维条覆层，首先由经电离的空气产生空气流并且将其引导穿过文丘里喷嘴，将粉末借助螺杆输送机从储备容器取出并且输送给文丘里喷嘴，并且沿流动方向在文丘里喷嘴的下游形成由粉末空气混合物构成的流并且将该流引入到腔室中，将接地的或与所述粉末相反电离的纤维条移动穿过所述腔室且穿过流动通过该腔室的粉末空气混合物，其中，粉末颗粒沉积到纤维条上，并且从该腔室导出的纤维条以此方式具有每单位时间或每单位纤维长度限定量粉末的覆层。将这样覆层的纤维条输送给塑化装置，纤维条由单螺杆或双螺杆拉入该塑化装置中并且被加入到熔化的塑料材料中，其中，制成由塑料熔体和纤维材料构成的混合物并且将所述混合物输送给成型装置。以此方式制造的纤维增强塑料成型件的特征在于，存在于塑料成型件中的纤维具有限定份额的覆层材料。
因此，按照本发明设置两种变型方案，以实现粉末材料在纤维条上足够的附着。在第一变型方案中，仅将粉末电离并且将纤维材料接地。如果希望或应要求较高的附着，则根据第二变型方案可设置，将粉末正电离并且将纤维条负电离(或反之亦然)。
通过选择覆层材料可实现其它优点。尤其是当覆层材料选择为使得在塑化装置中熔化的塑料的粘度在被输送的设有覆层材料的纤维条的直接周围明显降低时，可明显使纤维条的各个设有覆层材料的纤丝的润湿变得容易。具体来说，所述覆层的纤丝在最初与塑化装置中熔化的塑料材料接触时直接以所述塑料材料浸渍，然后这些纤丝才能被紧致成附聚物。通过早期避免形成附聚物，也不需要例如通过强剪切的分散区域分解这些附聚物。取消强剪切的区域又实现在构件中较大的平均纤维长度，所述纤维长度因此积极反映在机械特性中。
优选地，螺杆输送机以下方加料的方式运行。与文丘里喷嘴以及在那里存在的负压配合作用地形成封闭的系统。这具有如下优点：粉末颗粒计量加入的腔室形成用于紊流流动形态的足够空间，因为所述空间没有被沉积的粉末颗粒填充。所述紊流流动形态又实现粉末均匀地施加到所穿通的纤维条的整个表面上。
优选地，可在将空气引导通过文丘里喷嘴之前将所述空气加热。这有助于在形成粉末空气混合物时空气是尽可能干燥的。此外，由此纤维条也被加热，并且因此使在塑化装置中熔化的塑料材料(经覆层的纤维条被引入该塑料材料中)在与所述纤维最初接触时不被固化。因此，改善了纤维的润湿。
此外，可以有利的是，将空气加热到所述粉末颗粒熔化的温度。根据所使用的材料在或多或少高于110℃的温度时就是这种情况。
按照本发明的设备基本上包括纤维覆层装置、具有单螺杆或双螺杆的塑化装置以及成型装置。所述纤维覆层装置具有腔室，纤维条可被移动穿过所述腔室并且由粉末空气混合物构成的流可被引导通过所述腔室。按照本发明的设备的特征尤其在于，纤维覆层装置具有连接到所述腔室上且装备有文丘里喷嘴的空气通道，经电离的空气可通过所述空气通道被导向所述文丘里喷嘴并且穿过所述文丘里喷嘴，并且特征还在于，纤维覆层装置具有带有螺杆输送机的粉末储备容器，其中，螺杆输送机的出口端设置为使得由螺杆输送机输送的粉末可流入到所述文丘里喷嘴中并且与所述经电离的空气混合，以便能够产生由粉末空气混合物构成的流。
在一优选的实施形式中，所述腔室可在其上侧上具有膜片，该膜片是空气可透的，但对于所述粉末储备容器中的粉末是不可透的。这是有利的，因此对于均匀输送粉末所需的空气可从该腔室中逸出，但同样确保了计量加入的粉末量也完全施加到纤维上并且不会部分地与空气一起从该腔室中逸出。
优选地，在所述空气通道中可设置有加热装置，该加热装置沿流动方向优选在所述空气通道中设置在所述文丘里喷嘴的上游。由此，可干燥和加热所述空气。通过所述加热装置，可将空气加热到所述粉末颗粒熔化的温度。这改善了所述覆层材料在纤维条表面上的附着。
以有利的方式，可设置合适的、本身已知的电离装置，以便能够产生经电离的空气并且将其引入到所述空气通道中。由此，避免在所述空气通道本身中安装电离装置。
挤出工具或注塑工具可被设置作为成型装置。尤其是所谓的注塑成型混合机可设置作为注塑成型机，该注塑成型混合机具有单螺杆或同向旋转的双螺杆挤出机。
接下来要借助各实施例并且参照图1和图2详细描述本发明。
图1示意性示出按照本发明的设备的构造。附图标记1是指注塑成型机或挤出机，如它们相应本身已知的那样(参见，例如EP1144174B1、EP1306187B1或DE4236662C2)；因此，在这里可以省略对其的详细描述。附图标记2b是指如下纤维条，所述纤维条已被覆层并且被输送给注塑成型机或挤出机1的塑化单元。总体上设有附图标记3的纤维覆层装置基本上包括腔室4，该腔室4利用空气可透的膜片5封闭。在腔室4的下侧上连接有空气通道6。所述空气通道6装备有多个装置，即通风机7、加热装置8和文丘里喷嘴9。在文丘里喷嘴9的上侧上设置有漏斗10，作为粉末11存在的覆层材料通过该漏斗被引入到文丘里喷嘴9中。粉末11在储备容器12中被准备好并且通过螺杆输送机13从储备容器中被排出。螺旋输送机13的出口端设置为使得由螺旋输送机13输送的粉末11落入到漏斗10中并且因此可流入到文丘里喷嘴9中并且在那里与经电离的空气混合。因此，在文丘里喷嘴9的下游存在由粉末空气混合物构成的流。未示出本身已知的用于电离空气的装置。用箭头P1要仅示出，将之前已被电离的空气引入到通道6中。在箭头P2中，空气已经经过加热装置8和相应地被加热。
未覆层的纤维条2a在储备卷14或类似物上被准备好并且从那里被抽出。所述抽出借助该机器1中的塑化装置的一个螺杆或多个螺杆实现。纤维条2a要被接地。腔室4具有合适的进入装置和排出装置15、16，以便能够将纤维条2a尽可能无摩擦地拉入到腔室4的内部并且能够将覆层的纤维条2b从腔室4中导出。尤其是，所述进入装置和排出装置可设计成漏斗形的，如在图1中示出的那样。
按照本发明的设备的工作方式如下。如用箭头P1示出的，经电离的空气借助通风机7被吸入到空气通道6中、由加热装置8加热并且被引导穿过文丘里喷嘴9。在下方加料的运行中，准确测量的每单位时间的粉末量借助螺旋输送机13从储备容器12被引入到漏斗10中并且因此被引入到文丘里喷嘴9中。因此，空气通道6中的空气流被掺入准确测量的每单位时间的粉末量并且粉末由经电离的空气充电。该粉末空气混合物进一步流动通过空气通道6并且在腔室4的下侧处到达该腔室中。如用箭头P3示出的，空气通过膜片5被排出到室外。纤维条被横向引导穿过腔室4，其中，纤维条的基本上水平的位置是优选的。粉末空气混合物的流动方向基本上竖直地定向。当纤维条被移动穿过腔室4时，它们连续遭受粉末空气混合物，并且被充电的粉末可能沉积在接地的纤维条上。在此，准确测量的每单位时间的粉末量被施加到纤维条上。以这种方式覆层的纤维条2b被输送给机器1的塑化装置或者说由该塑化装置拉入并且加工到熔化的塑料材料中。以这种方式产生由塑料熔体和纤维材料构成的混合物并且随后将所述混合物输送给成型装置。
图2与图1区别如下，在该变型方案中在腔室4的底部处设置有用于管17的接头，该管延伸直到机器1的塑化装置。由此，在腔室4的底部处的粉末沉积物可通过管17被输送到该机器1的塑化装置的纤维进入开口中。这具有如下优点：能够防止粉末材料可能沉积在腔室4的底部处。因此可以确保，在完成成形的纤维增强塑料成形件中存在准确期望的粉末11的量。在所述塑料成形件中的粉末11的量因此由作为覆层材料存在于经覆层纤维条2b的纤维上的粉末11或者说粉末材料和直接被混入到熔化的塑料材料中且可以说在塑料成形件中分布地存在于经覆层纤维之间的粉末11或者说粉末材料组成。如果所述管具有非常细的流动横截面但具有大的长度，则空气从腔室4中该附加开口的排出可减少到最小。
附图标记列表
1 注塑成型机或挤出机
2a 纤维条(未覆层的)
2b 纤维条(覆层的)
3 纤维覆层装置
4 腔室
5 膜片
6 空气通道
7 通风机
8 加热装置
9 文丘里喷嘴
10 漏斗
11 粉末
12 储备容器
13 螺杆输送机
14 纤维卷
15 纤维进入装置
16 纤维排出装置
17 管

Claims (10)

1.用于制造纤维增强塑料成型件的方法，其中，将纤维条(2a、2b)覆层并且输送给塑化装置，所述纤维条(2b)由单螺杆或双螺杆拉入所述塑化装置中并且加工到熔化的塑料材料中，其中，制成由塑料熔体和纤维材料构成的混合物并且将所述混合物输送给成型装置，并且为了将所述纤维条(2a)覆层，首先由经电离的空气产生空气流并且将所述空气流引导通过文丘里喷嘴(9)，将粉末(11)借助螺杆输送机(13)从储备容器(12)取出并且输送给所述文丘里喷嘴(9)，沿流动方向在所述文丘里喷嘴(9)的下游形成由粉末空气混合物构成的流并且将所述流引入到腔室(4)中，将接地的或与所述粉末相反电离的纤维条(2a)移动穿过所述腔室(4)并且穿过流动通过该腔室(4)的粉末空气混合物，其中，粉末颗粒(11)沉积到所述纤维条(2a)上，并且从所述腔室(4)导出的纤维条(2b)具有覆层，将这样覆层的纤维条(2b)输送给所述塑化装置。
2.根据权利要求1所述的方法，其特征在于，以下方加料的方式运行所述螺杆输送机(13)。
3.根据权利要求1或2所述的方法，其特征在于，在将空气引导通过所述文丘里喷嘴(9)之前将所述空气加热。
4.根据权利要求3所述的方法，其特征在于，将所述空气加热到所述粉末颗粒熔化的温度。
5.用于实施根据上述权利要求之一所述方法的设备，所述设备包括纤维覆层装置(3)、具有单螺杆或双螺杆的塑化装置以及成型装置，其中，所述纤维覆层装置(3)具有腔室(4)，纤维条(2a)能被移动穿过所述腔室，由粉末空气混合物构成的流被引导通过所述腔室，其中，所述纤维覆层装置(3)还具有连接到所述腔室(4)上且装备有文丘里喷嘴(9)的空气通道(6)，经电离的空气能通过所述空气通道(6)被导向所述文丘里喷嘴(9)并且通过所述文丘里喷嘴，并且所述纤维覆层装置(3)具有带有螺杆输送机(13)的粉末储备容器(12)，其中，所述螺杆输送机(13)的出口端设置为使得由所述螺杆输送机(13)输送的粉末(11)能流入到所述文丘里喷嘴(9)中并且能与所述经电离的空气混合，以便能够形成由粉末空气混合物构成的流。
6.根据权利要求5所述的设备，其特征在于，所述腔室(4)在其上侧上具有膜片(5)，该膜片是空气可透的，但对于所述粉末储备容器(12)中的粉末(11)是不可透的。
7.根据权利要求5至6之一所述的装置，其特征在于，在所述空气通道(6)中或处设置有加热装置(8)，该加热装置沿流动方向优选设置在所述文丘里喷嘴(9)的上游。
8.根据权利要求5至7之一所述的装置，其特征在于，设置有电离装置，以便能够产生经电离的空气。
9.根据权利要求5至8之一所述的装置，其特征在于，所述成型装置具有挤出工具或注塑工具。
10.根据权利要求5至9之一所述的装置，其特征在于，设置有管(17)，所述管的一个端部安装在所述腔室(4)的底部处并且所述管的相对置的端部通入到所述塑化装置的开口中、优选通入到纤维进入开口中。
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