DE102008036693A1 - Verfahren zur Herstellung dünnwandiger Formkörper in Twinsheet-Technik - Google Patents

Verfahren zur Herstellung dünnwandiger Formkörper in Twinsheet-Technik Download PDF

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Publication number
DE102008036693A1
DE102008036693A1 DE200810036693 DE102008036693A DE102008036693A1 DE 102008036693 A1 DE102008036693 A1 DE 102008036693A1 DE 200810036693 DE200810036693 DE 200810036693 DE 102008036693 A DE102008036693 A DE 102008036693A DE 102008036693 A1 DE102008036693 A1 DE 102008036693A1
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Prior art keywords
contact zones
friction welding
deep
walled hollow
hollow body
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DE200810036693
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Timo Tobolla
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/081—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations having a component of vibration not perpendicular to the welding surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/266—Auxiliary operations after the thermoforming operation
    • B29C51/267—Two sheets being thermoformed in separate mould parts and joined together while still in the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B29C65/0609—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding characterised by the movement of the parts to be joined
    • B29C65/0618—Linear
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7377—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
    • B29C66/73771—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being amorphous
    • B29C66/73772—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being amorphous the to-be-joined areas of both parts to be joined being amorphous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7377—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
    • B29C66/73773—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being semi-crystalline
    • B29C66/73774—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being semi-crystalline the to-be-joined areas of both parts to be joined being semi-crystalline
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B29C66/83221—Joining or pressing tools reciprocating along one axis cooperating reciprocating tools, each tool reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91211—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods
    • B29C66/91212—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods involving measurement means being part of the welding jaws, e.g. integrated in the welding jaws
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91221—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91231—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature of the joining tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91431—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being kept constant over time
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/924—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/9241—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force or the mechanical power
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/96—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process
    • B29C66/961—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process involving a feedback loop mechanism, e.g. comparison with a desired value
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/06905—Using combined techniques for making the preform
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

Hohlkörper aus thermoplastischen Werkstoffen können im Twinsheet-Verfahren in einem Arbeitsgang hergestellt werden. Um dies auch für dünne Folien zu realisieren, werden die Kontaktflächen durch ein selektives Ultraschall-Reibschweißverfahren aktiviert.

Description

  • TECHNISCHES GEBIET
  • Die Erfindung betrifft ein Verfahren zur Herstellung von Hohlkörpern aus thermoplastischen Materialien, insbesondere amorphen und teilkristallinen Thermoplasten in dünnen Folien. Hierbei werden zwei in Formen tiefgezogenen Folien in noch plastischem Zustand durch Verpressen der Formen gegeneinander an definierten Kontaktzonen – insbesondere den Rändern – miteinander verbunden.
  • PROBLEMSTELLUNG
  • Es ist bisher nicht möglich, dünne Folien mit kleinen Kontaktflächen im Twinsheet-Verfahren sicher und gleichmäßig miteinander zu verbinden, insbesondere dann, wenn verschiedene amorphe oder teilkristalline Thermoplaste miteinander verschweißt werden sollen.
  • Da die Betriebsparameter, wie Temperatur der Werkzeuge und Folien, Abstände und Anpressdruck im Fortgang des Verfahrens driften und nicht so fein regelbar sind, dass Kontakttemperatur und Abstände mit vertretbarem Aufwand bis in den Mikrometer-bereich konstant gehalten werden können, ergeben sich bei dünnen Folien und insbesondere bei großflächigen Teilen zwangsläufig hohe Ausschussraten durch mangelnde Verbindung oder Fehlstellen durch Ausschweißung.
  • STAND DER TECHNIK
  • Das Prinzip des Twin Sheet Formings (TSF) ist im Grunde mit US 2.918.698 von Hagen/Hagen seit 1954 bekannt, wurde von Greig et al. bei Fa. Woodall/Michigan 1960 und 1965 perfektioniert (US ...69.521 und US 3.242.245 ) und über drei Jahrzehnte hauptsächlich in den USA praktiziert.
  • Hierbei kam nach US 6.454.557 und 6.659.758 zunächst eine parallele Bearbeitung zweier Formteile mit nachfolgender Zwischenerhitzung und Verpressung zum Einsatz, später mit US 6.659.758 und US 6.705.853 rationellere Verfahren, in denen die Teile in zwei gegeneinander laufenden Karussells vorgeformt und dann noch in plastifiziertem Zustand miteinander verpresst wurden.
  • In Verfahren, die vor allem Geiss seit 1988 ( DE 3825061 ff) und 1991 Tobolla ( DE 4117197 ) entwickelten, wurden Methoden der präzisen Fertigung durch Vorheizung mit Vorblasen der Materialien und Formung in übereinander angeordneten Tiefziehwerkzeugen, deren parallele Zusammenführung und Kühlung des Formteils in situ entwickelt.
  • Bislang ungelöst ist dabei jedoch die Verbindung dünner Folien und kritischer Materialien, wie PET, PS und PC, insbesondere dann, wenn nur kleine Kontaktflächen zum Verschweißen des Materials zur Verfügung stehen und sehr zuverlässige Verbindungen gefordert sind.
  • AUFGABENSTELLUNG UND LÖSUNG
  • Es ist daher Aufgabe vorliegender Erfindung, derartige Verbindungen präzise und mit sicherem Verschmelzen der Materialflächen auszuführen.
  • Dies wird erfindungsgemäß dadurch erreicht, dass in geeignete Passfedern oder -Bolzen, die normalerweise die Formen nur zum Fluchten bringen, Piezo-Elemente integriert sind, die bei Ansteuerung mit einer dem jeweiligen Folienmaterial und seiner Oberfläche angemessenen Frequenz eine in der Amplitude geringe, aber durch hohe Frequenz effektive Vibration der Formteile bewirken und dadurch einen zusätzlichen Reibschweiss-Effekt auf die Kontaktflächen ausüben.
  • Damit ist es möglich, die Prozesstemperaturen auf die für die Tiefzieh-Formung nötigen Werte zu beschränken und den für die Verschmelzung erforderlichen Energieeintrag an den Kontaktflächen durch Reibschweissen präzise nachzuregeln.
  • Dazu wird die Temperatur an den Kontaktzonen während des Tiefzieh- und Verpressvorganges überwacht und die Intensität des Reibschweissens entsprechend angepasst.
  • Zu diesem Zweck sind Thermo-Sensoren an den kritischen Kontaktbereichen in die Tiefzieh-Formen eingearbeitet. Anhand ihres Ist-Werts wird die Intensität des Reibschweissens so lange erhöht, bis die optimale Verschmelzungstemperatur des Kunststoffes erreicht ist.
  • Dabei werden Frequenz und Wellenform des Ansteuersignals nach Erfahrungswerten für den jeweiligen Folientyp und insbesondere seiner Oberflächeneigenschft durch die Taktfrequenz des Schwingungsgebers justiert. Hierbei werden aus Gründen der Umweltbelastung nicht hörbare Frequenzen, vorzugsweise im Ultraschall-Bereich bevorzugt.
  • Dagegen wird die Intensität des Ansteuersignals und damit des erforderlichen Energieeintrages durch die Regelung des Verstärkungsfaktors an einem Leistungsverstärker bewirkt, mit dem die Piezo-Aktoren angetrieben werden.
  • Die Erfindung wird nachfolgend anhand der Zeichnung 1 näher erläutert:
    Die Thermosensoren 1 und 2 messen die Temperatur an den Kontaktzonen 3 und 4 der Tiefziehformen 5 und 6. Diese Ist-Werte werden dem Komparator 7 zugeführt, der zusammen mit voreingestellten Soll-Werten 8 und 9 den erforderlichen zusätzlichen Energieeintrag durch Reibschweissen errechnet und mit seinem Steuersignal 10 den Frequenzgenerator 11 in seiner Schwingungszahl und mit dem zweiten Steuersignal 12 den Verstärker 13 in seinem Verstärkungsfaktor zur Erzielung des Leistungssignals 20 ansteuert.
  • Die Leistung des Verstärkers wird den Piezo-Stacks 14 und 15 zugeführt, die in den Führungsbolzen 16 und 17 in den Zentrierbohrungen der Tiefziehformen 5 und 6 angeordnet sind. Ihre Bewegung bewirkt die Relativbewegung der Tiefziehformen 5 und 6 gegeneinander und damit den zusätzlichen Energieeintrag an den sich aneinander reibenden Kontaktzonen 3 und 4 der an die Formen 5 und 6 durch den Unterdruck 7 und 8 anliegenden Folien 18 und 19.
  • ZITATE ENTHALTEN IN DER BESCHREIBUNG
  • Diese Liste der vom Anmelder aufgeführten Dokumente wurde automatisiert erzeugt und ist ausschließlich zur besseren Information des Lesers aufgenommen. Die Liste ist nicht Bestandteil der deutschen Patent- bzw. Gebrauchsmusteranmeldung. Das DPMA übernimmt keinerlei Haftung für etwaige Fehler oder Auslassungen.
  • Zitierte Patentliteratur
    • - US 2918698 [0004]
    • - US 3242245 [0004]
    • - US 6454557 [0005]
    • - US 6659758 [0005, 0005]
    • - US 6705853 [0005]
    • - DE 3825061 [0006]
    • - DE 4117197 [0006]

Claims (11)

  1. Verfahren zur Herstellung von dünnwandigen Hohlkörpern im Twinsheet-Tiefziehverfahren, dadurch gekennzeichnet, dass das Verschmelzen beider tiefgezogenen Formteile an den Kontaktzonen beim Verpressen durch Reibschweißen unterstützt wird.
  2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass das Reibschweißen durch Bewegung der Tiefziehformen gegeneinander bewirkt wird.
  3. Verfahren nach Anspruch 1 und 2, dadurch gekennzeichnet, dass die Bewegung der Formen im Ultraschall-Bereich erfolgt.
  4. Verfahren nach Anspruch 1 bis 3, dadurch gekennzeichnet, dass die Einbringung der Bewegungsenergie mit piezokeramischen Elementen erfolgt.
  5. Verfahren nach Anspruch 4, dadurch gekennzeichnet, dass die Piezo-Elemente in den Zentrierbuchsen zwischen den beiden Tiefziehformen angeordnet sind.
  6. Verfahren nach Anspruch 3 bis 5, dadurch gekennzeichnet, dass die Ansteuerung der Piezo-Elemente mit bistabilen Multivibratoren erfolgt.
  7. Verfahren nach Anspruch 2 bis 6, dadurch gekennzeichnet, dass Frequenz und Amplitude des Ansteuersignals geregelt werden.
  8. Verfahren nach Anspruch 7, dadurch gekennzeichnet, dass die Ansteuer-Frequenz vorwiegend dem Materialtyp der Tiefzieh-Folien angepasst wird.
  9. Verfahren nach Anspruch 8, dadurch gekennzeichnet, dass die Amplitude des Ausgangssignals durch einen Verstärker dem erforderlichen zusätzlichen Energieeintrag angepasst wird.
  10. Verfahren nach Anspruch 9, dadurch gekennzeichnet, dass der Verstärkungsfaktor nach der Differenz zwischen Ist-Wert und Soll-Temperatur an den Kontaktzonen der Twinsheet-Formen gesteuert wird.
  11. Verfahren nach Anspruch 10, dadurch gekennzeichnet, dass die Temperatur an den Kontaktzonen durch in die Kontaktbereiche der Tiefzieh-Formen eingearbeitete Temperatur-Sensoren erfasst ist.
DE200810036693 2008-08-06 2008-08-06 Verfahren zur Herstellung dünnwandiger Formkörper in Twinsheet-Technik Ceased DE102008036693A1 (de)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102016000325A1 (de) 2015-01-13 2016-07-14 Claus Weinert Vorrichtung zum Warmumformen von thermoplastischen Halbzeugen zu Formteilen

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2918698A (en) 1954-06-14 1959-12-29 Hagen Reinold Manufacture of hollow articles from plastics
US3242245A (en) 1960-11-15 1966-03-22 Woodall Industries Inc Process and apparatus for forming hollow plastic structure
DE3825061A1 (de) 1988-07-23 1990-01-25 Geiss Georg Maschf Vakuumformmaschine
DE4117197A1 (de) 1991-05-26 1992-12-03 Ernst Hombach Inh Rudolf Tobol Verfahren zur herstellung von kunststoffteilen und vorrichtung zur durchfuehrung des verfahrens
US6454557B1 (en) 1997-12-08 2002-09-24 Brown Machine, Llc. Thermoforming machine with linear recirculation of sheet holding frames
US6659758B2 (en) 1999-03-01 2003-12-09 Lars O. Ekendahl System for twin sheet forming
US6705853B1 (en) 2000-10-20 2004-03-16 Durakon Industries, Inc. Six station rotary thermoforming machine
WO2005118267A2 (en) * 2004-06-01 2005-12-15 Novo Foam Products Llc Method of molding load-bearing articles from compressible cores and heat malleable coverings

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2918698A (en) 1954-06-14 1959-12-29 Hagen Reinold Manufacture of hollow articles from plastics
US3242245A (en) 1960-11-15 1966-03-22 Woodall Industries Inc Process and apparatus for forming hollow plastic structure
DE3825061A1 (de) 1988-07-23 1990-01-25 Geiss Georg Maschf Vakuumformmaschine
DE4117197A1 (de) 1991-05-26 1992-12-03 Ernst Hombach Inh Rudolf Tobol Verfahren zur herstellung von kunststoffteilen und vorrichtung zur durchfuehrung des verfahrens
US6454557B1 (en) 1997-12-08 2002-09-24 Brown Machine, Llc. Thermoforming machine with linear recirculation of sheet holding frames
US6659758B2 (en) 1999-03-01 2003-12-09 Lars O. Ekendahl System for twin sheet forming
US6705853B1 (en) 2000-10-20 2004-03-16 Durakon Industries, Inc. Six station rotary thermoforming machine
WO2005118267A2 (en) * 2004-06-01 2005-12-15 Novo Foam Products Llc Method of molding load-bearing articles from compressible cores and heat malleable coverings

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102016000325A1 (de) 2015-01-13 2016-07-14 Claus Weinert Vorrichtung zum Warmumformen von thermoplastischen Halbzeugen zu Formteilen

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