DE102004052527A1 - Forming section of container, in particular bottle crate, involves foaming second plastic onto inner or outer surface of injection molded container sidewall - Google Patents

Abstract

The container section comprises two sections, each of different materials. A first section(14) forming a sidewall is injection molded as an integral part of the container and the second section(15) is foam molded onto an inner or outer surface of the container sidewall. The container is injected in a first molding tool, demolded and placed in a second tool for foaming of a second section(15). Foam is introduced into the closed second tool between the first sidewall section(14) and the adjacent tool wall and bonds onto the first section. Foaming of the second section occurs over the entire or almost entire inner or outer surface of at least one sidewall. A tool core(7) forms the tool cavity wall when foaming onto an inner side of the container wall. When foaming onto the outer side of the container wall a tool plate forms the tool cavity boundary. Both first and second sections of the container may be molded in the same tool in which case the shape and volume of the cavity are changed for the foaming stage by movement of a tool core or tool plates. Foaming may occur onto a first inner wall surface and adjacent areas of the latter as well as onto inward facing surfaces of columns forming part of the container. A step, 1-5mm thick, may be formed between the injection molded first section and the foamed section.

Description

The This invention relates to a method of forming at least a container section of a boxy container like bottle crate with side walls and bottom wall, wherein the container section from a first portion of a first material and a second one Section of a second material and the first section together with the container in one piece as Injection molded part produced and the second section with the first Section is connected.

Of the DE 40 22 884 A1 is a plastic bottle case with at least one handle to remove the box to remove. In this case, the grip part consists of a core element and at least one outer element, which surrounds at least the underside of the core element, wherein the core element has a different hardness than the outer element. The core element is preferably produced together with the box body as a one-piece molded part. Subsequently, the outer element is applied. In this case, preferably a two-component syringes is provided. An injection and foaming is also possible. Regardless of the manner in which the outer element is applied to the core element, the handle in the region of the outer element has a width which is greater than that of the core element.

In a transport container made of plastic after the DE 199 36 229 A1 In the area of its carrying handle, a separately manufactured component is used. A corresponding solution is also found in the DE 201 05 567 U1 again. In this type of training of the handle, there is the disadvantage that the insert must be inserted into the mold before the plastic is injected. This means that the insert must be precisely fixed in order to obtain a handle in a finished box, which meets the desired requirements. However, practice has shown that this is often not the case. Regardless of this is a disadvantage that the cycle times are undesirably prolonged by inserting the inserts.

Inserted in the handle area of boxes separately manufactured components is also from the DE 201 05 567 U1 and DE 299 24 066 U1 known.

In a profile strip for motor vehicles after the DE 17 55 596 End pieces can be molded on. For secure connection undercut recesses are provided.

In the DE 195 13 465 C1 an assembly of two parts to be joined is described, which consist of different materials and are overmolded. Anchoring can be done by dovetailed edges.

Of the The present invention is based on the problem of a method previously described type so educate, the container sections in the desired Scope desired Have material properties and / or geometries. Also, an aesthetic appearance or create a design that can exercise the function of origin.

to solution the problem is essentially suggested that the second Section flat on at least one inner and / or outer surface of a Seitenwandungsbereichs or a side wall is foamed. In particular, it is doing the second section on entire or nearly entire interior or Outer surface of foamed up at least one side wall.

Is flat in principle to understand that on a relatively large surface of a side wall of the second section foamed which extends parallel to the corresponding side wall and over the entire area has the same or substantially the same layer thicknesses.

deviant The prior art in particular an entire or almost entire side wall - be it outside surface, be it inside surface - with one second section provided, the material of which of the first section, from the container exists, may differ. Deviation does not necessarily mean this different material properties itself, but also can color design include. This is due to the teaching of the invention the possibility, a container like bottle crate inside to make differently colored than outside surface side and vice versa, where mentioned, in particular at least always an inner or outer surface of at least one side wall consists of a first and a second section.

In particular, the foamed second section offers the advantage that steps between the first and second section can be formed to the desired extent, wherein the thickness d (2 mm ≦ d ≦ 5 mm) of the second section can also be varied to the desired extent without there is a risk of default in the first section. In other words, due to the teaching according to the invention that plastic is partially foamed on the sprayed container, it is ensured that the dimensional stability of the container does not adversely affect is flowing. This is particularly advantageous in bottle cases, as they must have a high dimensional accuracy due to the requirement of stackability.

The Thickness d of the second portion may e.g. be (2 mm ≤ d ≤ 5 mm).

Independent of this the second section has to be in the true sense of the supporting function of the container do not exercise. Rather, the first section containing container is already statically designed so that the desired support function is met.

• – Spritzen des Behältnisses mit dem ersten Abschnitt in einem ersten Werkzeug,
• – Entnehmen des Behältnisses aus dem ersten Werkzeug und Einbringen des Behältnisses in ein zweites Werkzeug,
• – Schließen des zweiten Werkzeugs und Einbringen des aufzuschäumenden zweiten Materials in zwischen dem ersten Abschnitt und entlang diesem verlaufender Begrenzung des zweiten Werkzeugs ausgebildeten Geometrie des zweiten Abschnitts vorgebenden Hohlraum bei gleichzeitigem Verbinden des ersten und zweiten Materials und
• – Öffnen des zweiten Werkzeugs und entfernen des Behältnisses.

In particular, the invention is characterized by a method of the type described above by the method steps:

• Spraying the container with the first section in a first tool,
• Removing the container from the first tool and inserting the container into a second tool,
• Closing the second tool and inserting the second material to be foamed in the cavity of the second section between the first section and along this running boundary of the second tool, while at the same time connecting the first and second material and
• - Opening the second tool and removing the container.

there is provided in particular that the cavity from the mandrel of the second tool for forming at least one inner side wall or a section of this is limited. Alternatively, it is possible to that the cavity of a forming jaw of the second tool for Forming at least one outer side wall or a section of this is limited.

alternative the second tool can be designed such that the first and the second section injected in the same tool or frothed be, where for foaming of the second section according to its geometry and volume Mold core or mold jaw of the tool adjusted and / or changed in terms of volume.

Independently of, in which area of the container the second section is foamed, be it along an inner surface or along an outer surface of a Sidewall, it is provided that the second section on at least a first inner side wall surface and adjacent areas or adjacent areas adjacent second Innenseitenwandungen is foamed. It is intended that the second section also on surfaces of the container facing Holmen of the container frothed becomes.

deviant from previous proposals particularly according to the invention at least one inner or outer surface at least a side wall of a container like bottle crate provided with a second section, the a material which differs from that of the container at least from the Design or color deviates.

The second material may have different properties than the material of the container itself has. In this case, the second section extends in particular preferably also along adjacent sections of side walls, especially along existing in their areas Holmen.

The second tool can be a basic structure as the first Tool having only dimensional adjustments to the formation of the second section and the foaming behavior of the second material must be taken into account; because in the second tool must for the second material provided a cavity, on the one hand from a tool section and on the other hand from the to be sprayed Wall of the container is limited.

He follows mentioned that Foaming the second section preferably in a second tool, then exists also the possibility in one and the same tool both to spray the container as well to foam up the second section. In this case, it is only necessary that the limitations of the cavity to be charged by the second material by e.g. Adjustment of jaws or slides to be changed.

Further Details, advantages and features of the invention do not arise only from the claims, the characteristics to be taken from these - alone and / or in combination - but also from the following description of one of the drawing to be taken preferred embodiment.

It demonstrate:

1 a section of a tool,

2 a detail of the tool according to 1 .

3 opened nozzle side of the tool according to the 1 and 2 .

4 Ejector side of the tool after 1 and 2 with demolded foam container and

5 - 7 in perspective views cutouts of partially foamed containers

In the 1 to 4 are sections of a tool shown, with the according to the teaching of the invention in the 5 - 7 as a bottle crate 100 . 102 illustrated container outside or inside with a foamed plastic layer 104 . 106 . 108 provided by the bottle crate 100 . 102 desired optical or mechanical properties undergoes, which are geared to the particular application. Due to the foaming, it is possible to form a step between the box and the foamed layer 112 train as this is based on the 5 is clarified. So is on the sidewall outer surface or outside 109 of the box 100 the layer 104 foamed, which is also in the range of a handle 110 of the box 100 runs. Between the foamed layer 106 and the outside 108 of the bottle crate 100 the step passes 112 , which may have a desired depth, that is, material thickness d of, for example, 2 mm to 5 mm. By foaming plastic on the box 100 or its outside 108 There is the advantage that desired layer thicknesses can be foamed up without the risk of default for the box 100 itself grows up. In other words, the dimensional accuracy of the box 100 through the foamed layer 104 unaffected.

Based on 6 and 7 should be clarified that the bottle crate 102 not only along the outside with the reference numeral 106 characterized layer, but also inside a foamed layer may have (reference numeral 108 ). In this case, the layer extends 108 along the spars 114 . 116 , without these are filled with the foamed plastic, as the sectional view of the spar 116 clarified.

Around the box 102 inside and outside to the desired extent and in the desired thickness to be provided with a plastic foam layer, which intimately with the box produced by injection molding 100 . 102 joins, becomes the box 100 . 102 initially injected in a first tool, not shown, in the form of an injection mold. It is provided in particular that the with the foamed layer 104 . 106 . 108 provided area of the box 100 . 102 dimensionally equal to the remaining area where a foamed layer is not located. However, there is also the possibility of the areas of the box 100 . 102 dimensionally deviant, in which the layer 104 . 106 . 108 foamed, provided the bottle crate 100 . 102 continue to have the required static stability.

In the embodiments of the 5 - 7 have the wall areas that match the foamed layers 104 . 106 . 108 is provided, same sizing as the remaining areas.

After spraying the box 100 . 102 this is then in one of 1 to 4 to be taken and introduced in the neckline second tool introduced in the manner described below, the layers 104 . 106 . 108 to the desired areas of the box 100 . 102 froth.

The tool has a basic structure that corresponds to the injection mold, ie the first tool. Thus, the tool has a clamping plate on the nozzle side 1 , a spacer strip 2 , a mold plate 3 , a form of baking 4 , an actuating slide 5 , an actuator plate 9 , a distance column 10 , an actuating column 11 , a hotrunner 12 and a nozzle having a prechamber bushing 13 on.

On the ejector side, the tool comprises a mold plate 6 , a mold core 7 as well as an ejector frame 8th ,

When the tool is open, so with a spaced mold plate 6 , Mold core 7 and Auswerfrahmen 8th to the nozzle-side and previously explained tool parts of the bottle crate in the mold core 7 inserted to then close the tool. Here are form jaw and actuating slide 5 aligned with each other such that at Formkernseitiger outer surface of the mold block of the area of the bottle crate 100 . 102 lies, on which a plastic layer is to be foamed.

The fan-limiting walls of the bottle crate 100 . 102 run in in the mold core 7 existing slots, with sealing elements are provided to ensure that the introduced foaming material can not get into this area. Corresponding sealing elements are exemplified by the reference numerals 16 and 17 characterized.

As is apparent from the detailed representation according to 2 results in, via the nozzle, the second material in between the inner surface of in 2 with the Be reference numbers 14 provided side wall of the bottle crate 102 and to this spaced extending outer surface of the mold core 7 introduced to an inner layer 15 on the inner surface of the side wall 14 froth. The layer 15 is in 6 . 7 with the reference number 108 Mistake. In this case, there is an intimate connection between the side wall 14 and inner layer 15 respectively. 108 such that there is an insolubility. Optionally, the surface to be encapsulated may be structured - honeycomb or recesses and projections are to be mentioned by way of example - in order to additionally achieve, in addition to the intimate connection between the materials, a quasi-mechanical anchoring or toothing.

After the layers 104 . 106 . 108 foamed, the tool is opened. For this purpose, first the actuating slide by means of the actuator plate 9 and the actuation column 11 in the direction of the arrow 18 adjusted, causing the mold jaw 4 to the bottle crate 10 is spaced (arrow 19 ). Then, the ejection side as shown 4 spaced apart to the nozzle side to simultaneously by means of Auswerfrahmens 8th the bottle crate 100 respectively. 102 eject.

Claims (10)

A method for forming at least one container portion of a box-shaped container such as bottle crate with at least side walls, wherein the container portion of a first portion of a first material and a second portion of a second material and the first portion together with the container made in one piece as an injection molded part and the second section with is joined to the first portion, characterized in that the second portion is foamed flat on at least one inner or outer surface of a Seitenwandungsbereichs. Method according to claim 1, characterized in that that the second section covers all or almost all indoor or outer surface of at least one side wall is foamed. Method according to claim 1 or 2, marked through the process steps, - Spraying the container with the first section in a first tool, - Remove of the container from the first tool and placing the container in a second tool, - Close the second tool and introducing the foaming second material in between the first section and along this running boundary formed of the second tool geometry of the second section predetermining cavity while connecting the first and second material and - opening the second tool and remove the container. Method according to at least one of the preceding Claims, characterized in that the cavity from the mandrel of the second Tool for forming at least one inner side wall or a section of this is limited. Method according to at least one of the preceding Claims, characterized in that the cavity of a forming jaw of the second tool for forming at least one outer side wall or a section of this is limited. Method according to at least one of the preceding Claims, characterized in that the first and second sections be injected or foamed in the same tool, wherein for foaming the second section corresponding to its geometry and volume of mandrel or mold jaw of the tool adjusted and / or volume changed. Method according to at least one of the preceding Claims, characterized in that the second section is at least a first inner side wall surface and adjacent areas of adjacent second inner sidewall surfaces. Method according to at least one of the preceding Claims, characterized in that the second section on container interior facing surfaces is foamed by Holmen the container. Method according to at least one of the preceding Claims, characterized in that between the first and the second Section a step is formed. Method according to at least one of the preceding Claims, characterized in that the step through a thickness d of the foaming Layer formed with 1 mm ≤ d ≤ 5 mm becomes.