DE102010002843A1 - Process, installation and resin mat for producing fiber-reinforced molded parts in a molding press - Google Patents

Abstract

Process for the production of fiber-reinforced molded parts (SMC) by means of extrusion in a molding press (20), an associated flat belt system (16) for the continuous production of an endless fiber-reinforced resin mat (10) and a transfer device (19) in a direct process, whereby in the flat belt system (16) in a mixing device (1) at least one resin base layer (5, 8) is brought together with fibers (6), mixed in a subsequent milling and soaking device (14) and finally matured in a thickening device (25) to form an endless resin mat (10), and the endless resin mat (10) is cut into blanking mats (18) and subsequently transferred directly or to a scrim (36) with further blanking mats (18) by means of the transfer device (19) into a tool (35) of a molding press (20) and into the molding press (20) is pressed into a fiber-reinforced molded part (21), characterized in that by means of at least one transfer device Seal (19) at least two molding presses (20, 20 ') with the endless resin mat (10) produced in a flat belt system (16) and divided into finite blanking mats (18).

Description

The invention relates to a method for the production of fiber reinforced molded parts (SMC) in a molding press according to the preamble of patent claim 1 and further a plant for the production of fiber reinforced molded parts (SMC) according to the preamble of claim 14. Further, the invention relates to a resin mat for Use in a molding press according to claim 23.

Because of their good mechanical properties and the favorable price, such molded parts produced by the SMC process are the most widely used thermoset fiber composite plastics. So far, for the production of SMC parts, first the raw material, consisting of a resin composition (resin formulation) with embedded cut glass fibers produced. This resin batch is deposited on thin transparent plastic films (carrier films) and subjected to a ripening process. The current ripening process is 4-5 days and serves to thicken the resin batch with the blended fillers and / or the improved impregnation of the glass fibers. The resin formulation consists of resins, thermoplastic solutions, fillers, flow improvers, integrated release agents, inhibitors and hardeners. This is stirred to a well-dispersed liquid to a predetermined temperature and still provided on the resin mat system with a thickening agent, powder or liquid, and knife-doctored onto the lower and upper carrier film and adjusted in width. On the resin base layer of the lower carrier film, the cut glass, for example, of endless rovings with cutting units, is added. Thereafter, the upper carrier film with the resin approach to the Schnittfaserbelag. Through a subsequent milling process, the fibers are mixed / impregnated with the resin batch and then wound as a resin mat on a roll or temporarily stored as a flat semi-finished product for the ripening process. Due to the ripening process, the resin batch thickens so much that the carrier films can be removed without residue. From the flat semifinished product or the rolls, blanked mats are cut out, matched to the particular molded part to be produced, and simply placed in a molding press or as a package and pressed ( 1 ). This known SMC method has now been supplemented by an optimized method. This D-SMC process requires no maturation time or maturation time is shortened by adjusting the resin used or by the additives such that produced after discharge from a flat web plant as a manufacturing device for the SMC semi-finished directly in a molding press the SMC end product can be. It eliminates a lengthy or multi-day waiting period of maturation.

With EP 1 386 721 A1 a method and a plant has become known, which was based on the object to provide the resin mats (SMC semi-finished) with the appropriate plasticity for immediate direct processing into moldings. Particular preference should be given to dispense with films and the control of the ripening time or the thickening time of the resin mats was carried out essentially the heat input in a tempered thickening flow memory. Meanwhile, the continuous direct process for the production of fiber-reinforced molded parts without intermediate storage of resin mats for the ripening process in industrial life is realized and has clear advantages in the field of just-in-time production, with significant problems of warehousing and especially the just-in-time Delivery can be avoided. Especially it is to be emphasized that with EP 1 386 721 A1 a compact system as possible has been disclosed, in which in a thickening flow memory for a timed ripening process, depending on the required length, the temperature-controllable tape carriers meandering were arranged in a housing. By arranging the strip carrier and their execution in length and number one above the other, the ripening process can be designed with appropriate maturation.

Basically, this system has proven itself, but has lack of flexibility in highly industrial operation. In particular, it is disadvantageous that in the case of already slight deviations of the wall thickness in a workpiece to be formed, SMC mats or SMC mat mats adapted thereto must be introduced into a molding press. Usually, this is a resin mat cut or made of parts and / or more uniform resin mat a clutch with a pattern that is composed manually or automatically by means of industrial robots and inserted in its entirety in the tool. Such mat coverings must always be designed for the individual case and the robot or system control must be taught in each time the tool is changed. This costs programming time and also significantly increases the maintenance effort. Furthermore, in the production of simple components underutilized system technology is present if no or only very simple Mattengelege must be put together. Another aspect is that the normally homogeneous and uniform SMC resin mats must be regularly adjusted to the workpieces to be formed, for example, by rolling, drawing, stretching or cutting.

Especially for special molded parts, which have a place of extreme bending stress or a planned breakthrough nowadays be created manually or automatically scrims made of specially cut resin mats, the take into account special requirements of the molded part. A necessary breakthrough is usually used in moldings for mounting of other moldings. By way of example, a filler neck on a fender or, for a bumper, openings for auxiliary headlights, turn signals, towing lugs should be mentioned. These breakthroughs have the task to collect common machine elements or release a passage and thus partially a regular stress in the insertion area (wind, flap mechanisms ...) are exposed. The previous manual or semi-automatic additions of these reinforcements in a tool directly or in a clutch prevent automated production and are largely inaccurate and inflexible in production changes. Also arise in the addition areas unwanted layers of material, which in turn make the subsequent integrity of the molding in question.

Usually, therefore, the resin mats produced in the flat web plant are cut to cut mats and compressed in a D-SMC process (direct production and compression just in time) within the available press time window. In addition to the above-mentioned low flexibility of the entire system, it is necessary to reduce or even halt production during tool changes or during tool or press repairs or necessary cleaning processes. Even unforeseen problems with the press or the tool lead to production interruptions. However, flat rail systems are known to produce the best quality in continuous production, even if it is slower.

The object of the invention is to provide a plant and a method for operating a plant for the production of fiber-reinforced resin mats for the direct production of SMC molded parts, which has a much greater latitude and a simplified system technology in terms of the possible production amount per unit time and / or production based on the need for the prior art. In particular, the task is to be solved that resin mats for SMC production Just in time to be produced and pressed directly, with production losses should be avoided by maintenance, set-up or cleaning work on a molding press or on their tools. In an extension of the task not only uniform SMC mats with a predetermined volume or a predetermined width or height can be produced, but that based on a workpiece to be produced in a molding press a suitably adapted and appropriately shaped SMC mat is created, the either can be compressed directly without additional effort (jaw creation) and / or significantly simplifies the formation of a jelly from cut mats or reduces the number of necessary cut mats of a jelly.

The solution of the problem for the method is that by means of at least one transfer device at least two molding presses are produced with produced in a flat belt system and divided into finite blanking mats endless resin mat.

The solution of the problem is for a system in that at least two compression molding presses are arranged in the system for pressing the produced in the flat belt system and divided into finite blanking mats endless resin mat.

The solution for a resin mat is that the resin mat produced in a flat belt plant has in its height and / or across its width a differentiated contour and / or at least one reinforcing means consisting of reinforcing means with respect to one of the two molding presses. In an extension of the solution it is provided that the resin mat is adapted in at least one contour and / or at least one reinforcing region to a tool or at least to a part of a tool in a molding press.

According to the invention, it is now provided that a flat rail system serves several molding presses. The molding presses can drive different tools that are fed as needed (pressing time of a tool) with the blanking mats.

For example, a press with a three-minute pressing time in a press to be fed in parallel with a six-minute pressing time can be charged twice with the resin-mat contours assigned to it before a resin-mat contour or a cutting mat for the second press is produced.

• – mehrere Formpressen mit unterschiedlichen und auf die vorhandenen, insbesondere unterschiedlichen, Werkzeuge abgestimmten SMC-Matten versorgt werden können,
• – Industrieroboter in erster Linie nicht zur Erstellung von Mattengelegen, sondern vorzugsweise nur zur Übergabe zwischen Flachbahnanlage und Formpresse Verwendung finden,
• – unterschiedlichste Werkzeuge (Volumen- und/oder Zeitbezogen) in einer oder mehreren Formpressen Verwendung finden können oder
• – extrem hochreaktive Harzansätze verwendet werden können, die ein sehr geringes Zeitfenster zur Verpressung aufweisen.

Advantageously, it is now possible with the inventive system or with the method of the tool in one or more molding presses adapted to produce resin mats for direct use

• - several molding presses with different and on the existing, in particular different, tools matched SMC mats can be supplied,
• - Industrial robots primarily not for the creation of mats, but preferably only for the transfer between flat track and molding press use,
• - Can use a variety of tools (volume and / or time) in one or more compression molding or use
• - Extremely highly reactive resin approaches can be used, which have a very short window for compression.

Advantageously, it is now possible by means of the method according to the invention and a proposed system to produce special reinforcement regions in the interior of an SMC resin mat in an automated and simplified manner, and to feed at least two molding presses. In particular, it is advantageous if the molding press have different tools that require different contours or reinforcement areas and the flat web plant according to the needs of the molding presses provides the necessary and optimally made for the tools different blanking mats from the endless resin mat available. By means of a suitable application device, for example an industrial robot and / or an outlet nozzle for resin approach and / or a traversing scattering device for fibers, the reinforcing regions are developed or deliberately deposited so that they fit in a contour ratabschitt and later in the corresponding blanking mat to the corresponding tool in a molding press respectively arranged for the molded part to be produced. Thus, topographical patterns can be formed on a resin formulation, for example by means of a film applicator for the resin formulation or by means of suitable devices to form the already finished reinforcement regions in advance and place them according to the specifications on the resin formulation layer. Other fibers, longer fibers, woven fiber inserts, directed fiber agglomerations or the like can be used here.

With regard to the terminology used, the following definitions apply: Under a resin mat with a variable contour, the invention relates to a resin mat which has at least one differentiable difference in its width b and / or height h after being cut into a blank mat of a predetermined length the supply of one or more molding presses or their tools is adjusted. With regard to the fibers, the invention understands the changed amount entry such that in the resin mat or in a blank mat over the length and / or the width of a different amount of fibers is present. This is due to a change in the spread rate across the width of a continuously continuous (conveyor) belt below. Preferably, the scattering of the fibers is also adjusted across the width of the set width of the Harzansatzaustrages so as not to unnecessarily contaminate the conveyor belts and / or to minimize material losses.

It is assumed that the supply of resin batch for Aufrakelung on films or conveyor belts is basically ensured and this can either be delivered in an appropriate amount or produced on site with suitable manufacturing equipment. The advantages listed above are particularly important when several molding presses are altogether arranged in a production facility for SMC components. In particular, it is preferred that a complete and automated control of the overall system from at least one resin mat production and at least one, preferably a plurality of molding press is arranged with interposed between these two main elements transfer device. Technically, the individual plant parts are interconnected and controlled so that production interruptions or maintenance in the molding presses can be automatically controlled so that the transfer device and / or the relevant part of the plant for the production of resin mats optimized for the provision of resin mats provide on the compression molding, depending on the necessary Requirement. The essence of the molding press or their tools is that for all prescribed pressures a minimum cleaning of the tool is provided. There are also maintenance intervals, which also occur at regular intervals, but only take a few minutes. The control device controls the resin mat production in the flat web plant in such a way that, depending on the expected requirement for resin mats by the press controls, the necessary number of contour-matched resin mats can always be transferred. At the same time, the control device prevents over-production of resin mats due to the maintenance or cleaning intervals, which can not be processed.

Furthermore, the production plant can respond optimally to production changes / changes and not only has to be satisfied with the variation of the strip speed and the discharge volume with uniform resin mats. Alternatively, in this context, at least one additional parameter, in particular the heat input into the resin mat during maturing, can be changed. Particularly preferred in this context is a microwave arrangement is used, the heat input. regardless of the stored respectively leading bands of the flat railway system, can bring in the resin mat. Heat transfer by convection is certainly within the scope of the feasible and usual, but high-quality tapes for transporting the resin mats, especially when no films are used, but usually have good insulating properties. In a particularly advantageous manner, the heating, preferably an HF or a microwave heating, connected by means of a time and / or path control with the resin mat production device (flat web), so that the heat input exactly on the different volumes (different heights and widths) of a resin mat section can react. Partial overheating or insufficient heat input should be avoided as far as possible. It is also conceivable that a part of the thickening section is rigid and a second part of the thickening section is variable in length, so that, in particular in large installations, preferably the thickening section physically consists of two devices, a rigid and / or a thickening section that can be changed in length respectively thickening device.

With regard to the transfer device, it should be noted that this essentially can consist of several functional parts of the plant which can not be further elaborated or presented, since not all possible variants of plant types or variations can be discussed. However, in the sense of the invention, the transfer device comprises the region from the exit point of the resin mat from the area of resin mat production. Preferably, this exit point is identical to the end of the main ripening time of the resin mat. In the nature of resin mats, it is, however, that this time depends on many factors. There is more of a main maturity window here, defined by the times "earliest possible processing" and "latest processing". The times outside the main ripening period result in either immature or overripe resin mats which essentially can not or can not be crimped. With regard to the latest processing, of course, time must still be taken into account for the transfer device or until it is inserted in the molding press. A transfer device preferably consists of a cutting device, an optional device for withdrawing the optional films from the resin mats, an optional device for assembling a resin mats from one or more resin mats, an optional device for transporting the resin mats / -gelege to one or more molding presses and a corresponding transfer device for transferring the resin mats / -gegege in a molding press.

As an advantage and result of all process steps and features of the plant according to the invention fiber-reinforced blankets, said fibers are preferably cut glass of rovings and / or long fibers or short fibers to improve the rigidity of the SMC molding, with the correct plasticity in an SMC direct process the further processing are fed to fiber-reinforced thermoset molded parts, that is, the SMC direct method of the invention is able to provide highly reproducible long fiber reinforced thermoset materials available to the processor, which are also tailored to the exact contour of the mold of a molding press. For this purpose, the resin mats are produced with partially diverging volumes of resin batch and / or fibers, wherein during production in the mixing device different production volumes per unit time are set by means of a control device. To adjust the production volume per unit time, the discharge height and / or the discharge width of the resin batch and / or the discharge amount of the fibers can be changed. Preferably, the endless resin mat is subdivided into contour rat sections which essentially correspond in length to the blank mats. For this purpose, the change of the resin mat is performed in sections or per unit time. It is also conceivable that for heavy contour cuts or changes, the (transport) belt for the resin batch is briefly stopped to allow the actuators to adjust the changed width or height of the resin batch.

It is also conceivable that the contour is not uniformly changed across the width, but that also differentiated contours across the width in the creation within a resin approach are possible. Here, the squeegee is divided across the width and differentiated adjusted in their height adjustment, for example, by a main squeegee for a basic Harzansatzschichthöhe and associated squeegee shifters, preferably several arranged across the width, which selectively retain or release the resin approach. There are traces in the production direction with different heights. Such a continuous or stepped increase could alternatively also be formed by an additional applicator (slot die) after a resin coating layer has been clipped onto a belt or a film.

Preferably, the variable contour is adjusted in height h and / or width b and / or the amount of fibers of the resin mat, according to the requirements of the moldings to be produced in the molding press. It is particularly advantageous if the resin mat is heated between the wiping and impregnating device and the blanking device by means of at least one heating device. The heat energy to be introduced into the resin mat should be adjusted by the heater to the different contours of the resin mat. As a heating device offers a microwave or high frequency heating. For setting the contours, the control device can at least one adjusting device for adjusting the width b by at least one movable side wall of a doctor blade and / / or the control device at least one adjusting device for adjusting the height h by at least one movable doctor blade and / or the control device to control the Faserzuführvorrichtung for adjusting the amount of fibers. For complex workpieces several consecutive Konturmattenabschnitte the same or different contours can be assembled into a scrim and pressed in a mold of a molding press to form a molding.

Normally, the chopped glass / fibers should always be covered on both sides with resin filler mixture, since otherwise partially dry fibers would adhere to the resin mat in the production process. In the case of a differentiated layer structure, therefore, a multilayer structure of the resin base layers should be used. Here, for example, the lower resin layer is covered with fibers in the same contour and with a cover layer of resin approach (layer) with the same contour. These two resin layers would be generated congruent and correspondingly timed over the two doctor blades. An additional intermediate layer with a different (differentiated) layer can also take place via a cutter movable in the directions b / s (x / y) and a b / s (x / y) movable resin discharge head (for example with a slot nozzle). In order to obtain the correct structure, the resin of the second contour should first be applied to the fiber layer of the first contour. Thereafter, the order of the fibers on the second contour and finally on the upper film, the resin layer of the first contour. In general, where less Harzfüllstoffgemisch (HFG) are gergerelt, also proportionally less chopped fibers are applied in order to maintain the same mixing ratio or even deliberately deviate therefrom. Hollow glass spheres for reducing the weight of the component can either be incorporated in the HFG in the extruder or else be sprinkled onto the resin or fiber layer. In principle, the individual contour sections can also be split longitudinally at least once in the direction of production (for example, with a central section). The longitudinal section can also follow a contour, wherein the outer contours on the left and right do not necessarily have to be identical. For example, could be fed with a resin mat contour of the same length two different tools two or a molding press, the right contour (the long side) does not have to be identical to the left contour (long side).

The targeted introduction of reinforcement areas in moldings, preferably at locations of excessive or extreme bending stress or, for example, planned breakthroughs in the molded part is thus easy to accomplish. It now results in the simple possibility to apply exactly at these areas a higher fiber content for higher rigidity, so that edge fractures are largely excluded. The opposite, an increase in the mixture in the direction of resin approach would be conceivable so that the molding can react more flexibly in certain areas to bending stresses. For this purpose, additional resin batch could be introduced into or onto an existing resin batch. A person skilled in the art also understands a resin filler mixture in the resin batch mentioned here in which fillers, such as chalk or hollow glass spheres, have been introduced into the resin batch. A conceivable application device for a reinforcement zone to be applied after a doctor blade, or a reinforcement region which is not limited to discontinuous and limited reinforcement regions but also comprises continuous linear reinforcement regions, would be conceivable as a discharge nozzle in slit or round shape with a corresponding associated delivery pump. An extruder with discharge nozzle, an applicator roll, if necessary with a paring knife or similar devices would be possible. With regard to the fiber entry, in addition to the short or long fibers mentioned, it would also be possible to use an endless fiber or a sliver, fiber fabric pieces, nonwoven fabrics or fiber scrims, which may have one or more layers. Preferably, the strength-promoting deposits are pre-impregnated, thus, for example, have already a possible continuous coating with resin approach to fibers. Examples of this would be continuous fibers which run through a impregnation station in front of a comminution device or are applied endlessly to a resin formulation layer directly after the impregnation station. Also unidirectional, preferably impregnated, fiber ribbons (fiber tapes), fiber fabric pieces, fiber fabric, nonwoven fabric or the like are usable. The transfer of cut fibers to a resin formulation layer would preferably be a cutting head with a punctiform or linear applicator device that can apply local reinforcements to any location on the SMC mat through an x / y linear drive to create the reinforcement regions. In the case of unimpregnated material for creating a reinforcement region, it may be sufficient to apply a second resin formulation layer to the reinforcement region or to introduce a layer of the resin filler mixture selectively or linearly in order to provide the unimpregnated material with sufficient resin formulation or resin filler mixture for impregnation in the rolling and soaking zone. Reinforcement areas made of continuous fibers can be unwound in a targeted manner via a driven roller pair. Also, such a pair of rollers can be moved in the x / y direction, preferably with a suitable linear drive, wherein preferably the continuous fibers are fed into tubes. The continuous fibers can also transversely to the direction of production or angular to be oriented. The applicator can also have a cutting device (cutting shear) for targeted cutting. Fiber ribbons (also called fiber tapes) can be impregnated or unimpregnated. For the order, an unwinding station is provided as an application device, which is similar to that of the continuous fibers. Under certain circumstances, a longitudinal cutting device of two axially parallel to each other arranged cutting rollers is provided to reduce the width of the sliver. Fiber fabrics, fiber fabrics or nonwovens are usually punched or cut out of roll goods. Then you can be fed by means of an industrial robot or on a conveyor belt to the correspondingly defined position on the resin formulation layer. The depositing takes place via a gripper of the industrial robot, suitable transfer systems (gripper with x / y linear drive) or corresponding roller conveyor systems. Overall, one promises of roll tape systems an advantage because this suitable as an intermediate conveyor device to serve as a Vorablage for a fiber fabric or fabric to be produced. This has the advantage that, if necessary, further away from the belt of the flat web system by means of separate devices, these can be produced and completed according to the needs supplied by the roll band system and can be stored directly or in one piece. This results in the possibility even complicated contours directly generated, produce and store, for example, in a 3D CAD environment. The blank mats are pressed in the further course of the process directly to moldings or it will be composed of several blankets scrims, which are finally pressed. Usually, the blanking mats are smaller than the tool geometry, so that a flow process is created during extrusion. The blank mats are therefore preferably made proportional to the tool geometries. They are preferably oriented according to the tool inserted.

Additional reinforcement means are locally limited, but also in tracks along and / or across and / or localized conglomerates in the resin mat introduced. The means for reinforcement are localized with respect to the resin formulation layer, which means that the means for reinforcement are not applied over the entire surface. The obvious difference in terminology is that in the manufacture of SMC resin mats a usual amount of reinforcing fibers is introduced, which is carried out uniformly over the width and above all over the entire surface. The additional reinforcement means in question are to be considered as additional reinforcement means for this entry on full-area reinforcement, which are intended to locally and limitedly support the introduced "usual" fiber reinforcement.

Further advantageous measures and embodiments of the subject matter of the invention will become apparent from the dependent claims and the following description with the drawing. The following illustration is not to be regarded as a case-by-case solution, but in parts also contains general information and task solutions.

Show it:

1 an exemplary plant for the continuous production of fiber-reinforced resin mats in the course of the production of fiber-reinforced molded parts by extrusion in a molding press in a schematic side view with a production direction from left to right, wherein the resin mats are produced between two endless belts,

2 a top view of the lower doctor blade and the lower (transport) tape showing a possible contour of the resin mat in width,

3 a side view of the mixing device according to 1 with a representation of a possible repeating resin mat contour in the height of the resin mat,

4 a schematic side view of a resin mat contour as blanking mat and an example corresponding tool in a molding press,

5 a schematic plan view of a nest of several blank mats of different contour for pressing in a mold of a molding press,

6 a schematic representation of a control and / or regulating device with a Mindestnötigen number of linkage of the individual system components for carrying out the method in the control and delivery of multiple molding presses with optimized blanking mats,

7 an exemplary representation of a differentiated contour across the width of a resin mat in section,

8th an extension of a possible installation by an application device for introducing reinforcement areas onto a resin attachment layer of a resin mat to be produced,

9 a representation of possible adjusting devices and possibly associated squeegee shifters for changing the height of a resin formulation layer across the width in the preparation of a differentiated contour of a resin mat after 7 and

10 a collection of exemplary applicators or reinforcing means to be applied for the introduction of reinforcing regions in a resin mat to be produced.

1 shows a system that can also be used to carry out the method suitable but also independently, in a side view. It consists of the production of fiber-reinforced molded parts (SMC) by extrusion in their distinctive parts of a mixing device 1 with a Harzansatzaufbringstrecke A, the Walk and Tränkstrecke B and the Eindickbereich C. A mixing station for mixing the individual components or a dosing bunker for the resin formulation 9 is not shown. The plant after 1 shows a plant in which in the mixing device 1 , the walker and drinker 14 as well as in the thickening pass memory 25 as a flat railway system 16 no disposable films must be used, but two reusable, endless tapes 2 and 3 holding the resin mat 10 over pulleys 22 lead through these parts of the system. A usually necessary vent line was not shown for reasons of clarity, but can be part of the flat web 16 be. Certain resin approaches, in particular strongly adhesive or with the tapes 2 and 3 However, resinous coatings provided with chemical feedstocks can still be applied to the tapes 2 and 3 presuppose disposable films. The premixed resin batch 9 is done with the squeegee 4 on the lower band 2 to the resin formulation layer 5 knife. On this lower resin formulation layer 5 then become fibers 6 cut from chopped glass as long or short fibers. It is also possible, in particular for load-bearing parts or geometric features in the molded part, to generate reinforcing regions through the insertion of additional continuous fibers, fiber mats, further resin attachment layers in the required geometry. For this purpose, an application device 38 arranged arbitrarily. The applicator 38 preferably has at least one cross-beam 37 on where the applicator 38 can be moved by means of suitable linear conveyor in and across the direction of production or for height adjustment. It would also be conceivable in place of the applicator 38 an industrial robot (not shown) with the targeted and possibly recurring storage of reinforcing agent to form reinforcement areas 38 to commission. At the same time, the resin attachment layer is knife-coated 8th by means of the squeegee 7 on the upper band 3 , After combining the two resin formulation layers 5 (with the fibers 6 ) and 8th and their insertion between the lower and upper rollers 11 and 13 becomes the resin mat 10 in the walk and drink course B (Walk and drinker 14 ), wherein the fibers 6 with the resin approach 9 soaked and zusammengewalkt. The so-shaped endless resin mat 10 then becomes mature through a thickening device 25 guided. In the direction of production before the thickening device 25 can be a heater 24 be arranged, preferably a microwave device. Is the resin mat 10 it is matured by male connectors (not shown) from the tapes 2 and 3 detached and the cutting device 17 , preferably a transfer device 19 belonging, supplied. In the cutting device 17 becomes the resin mat 10 cut as required in length and / or in width, and means in the transfer device 19 arranged transfer means, here a conveyor belt, as blanking mat 18 the molding press 20 fed and in the molding press 20 to the molding 21 pressed and hardened.

2 shows a plan view of the lower doctor blade and the lower band 2 with representation of a possible contour 34 on the long side 27 the resin mat 10 in width b. For setting the contour 34 can the width b of the discharge of the squeegee 4 by means of the lateral movable side walls 29 be set. In the present example, there is a uniform movement of the sidewalls 29 , so that a wavy contour is created.

Was aware of the upper squeegee 7 omitted in the presentation in order to keep the drawing as simple and clear.

It should be noted, however, that in addition to the possibility of both squeegees 4 . 7 according to their distance from each other or depending on the meeting point of the two resin formulation layers 5 and 8th coordinated and / or correspondingly at the same time, to adjust in their width b of the discharge and the variant is conceivable, only a squeegee 4 or 7 in terms of width and / or height adjustment to control. This is in 2 by the dashed border of the resin formulation layer 8th' shown. This would not fundamentally be the width b of the resin mat 10 through the squeegees 4 and 7 on the long sides 27 changed (contour 34 would be linear), but there is a change in the volume over the width b, ie transversely to the production direction. The change leads to a differentiated contour 40 the height h over the width b of the resin mat 10 between the tapes 2 and 3 , see. this is the sectional view on the right side of the 2 , The sectional view shows a longitudinal side which is uniform over the width b 27 because the resin base layer 5 with a different contour (in this case with a linear long side 27 ) of the resin formulation layer 8th' has been overlapped. This results in lower volumes or densities in the edge areas on the long sides 27 the resin mat 10 , Preferably, however, such a variant would be carried out with three resin attachment layers and preferably the middle resin attachment layer with a differentiated contour.

Advantageously, the fiber content would be easily spread over the entire width b and on the long sides a smaller proportion of resin approach would be adjustable without the necessary fibers, especially important in thin areas of the molding, lost or only on the surface (a resin formulation ) remain. A specialist recognizes the many possibilities offered by the proposed setting options and the variety of possible variations in this context.

Preferably, however, the width of the fiber entry is adapted and / or the width adjustment reversed in relation to the doctor blades shown adjusted so that the fibers always fall on a resin base layer or are stored. For the purposes of the invention, therefore, the width adjustment is also understood in the sense of a volume change, so that the term contour substantially on the thickness, the density or volume change over the width and length of the resin mat 10 , respectively the blanking mat 18 can relate. Furthermore, it is of course conceivable that only one longitudinal side 27 the resin mat 10 or alternating the longitudinal sides through the side walls 29 to be changed. For sawtooth or edge-shaped contour sections, it is conceivable the production speed of the flat web plant 16 stop briefly or reduce the production speed until the appropriate adjusting devices 30 the side walls 29 moved to their respective position. Flexible flat rail systems 16 are able to do this, alternatively, in the flat railway system 16 For this purpose, a buffer system may be provided that compensates for the stop in the Harzansatzaufbringstrecke A and it allows the Walk and Drinking section B and / or the Eindickstrecke C continue to run continuously.

Preferably, the fiber feeding device 28 , preferably as a chopped glass or as a cutting unit for continuous fibers, also over the width sections and / or adjustable in relation to the Austragsmenge and variable. A person skilled in the art clearly recognizes the advantages of this embodiment and can now, especially in thin areas (cf., for example, the contour 40 to 1 right) of the resin mat 10 less fibers 6 be sprinkled around a "shine through" of the fibers 6 on the surface of a workpiece or molding 21 to avoid. It should also be possible to easily achieve predetermined mixing ratios between resin batch and fibers. Of course, the fiber feeder should 28 according to the lateral adjustment be controlled to the contour 34 to follow suit and not unnecessary fibers 6 on empty areas of the tape 2 to scatter. Also, the amount of fibers 6 specially adapted to difficult flow areas of the tool. Fibers are fillers or reinforcing agents such as rovings, short cut or long fibers, which are known and widely used in industrial applications and are suitable for fiber-reinforced material applications. Next hollow glass spheres, slivers, fiber fabrics, oriented fibers, metal inserts and fibers are found with a very long cutting length, which are preferably placed on the resin approach. In particular, the latter enumeration is used for local gains.

3 further shows a side view of the mixing device 1 to 1 with a representation of a possible repeating resin mat contour in the height h of a resin mat 10 , Compared to the previous figure here is the upper band 3 visible in parts. The schematic coordinate system sets in its longitudinal extension of the x-axis as in the previous figure, the process over the time t or the path s of the resin approach 5 . 8th respectively the resin mat 10 dar. The exemplary Kontormatte 32 shows in the contour 33 a recurring pattern of elevations that may be followed by a width adjustment 2 can correspond. These raises in the contour mat 32 are tuned to the contours of a tool 35 in a molding press 20 , The adjusting devices 31 move the squeegee 4 in height h and generate the contour 33 the resin mat 10 , As already described, the height adjustment of the squeegee 4 possibly also be sectionally adjustable over the width b, so that there are longitudinal strips of different height across the width, which in turn based on a contour mat 32 or on the entire resin mat 10 may have different heights h.

It is clearly recognizable which possibilities are now available to the person skilled in the presented method and the system when the contours 33 and 34 adjustable in every imaginable variability and especially on the tools 35 in one or even several compression molding machines 20 are adjustable. In particular, this solution can be used to directly load complex tools 35 in compression molding 20 allows and / or the creation of layers of blankets 18 for molding 20 be significantly simplified, because crucial bodies for flow molding in the tool 35 already optimized in width, height and / or in terms of fiber content in the resin mats 10 can be adjusted and not be improved by cutting or additional cutting parts. In high-quality plants, multi-layered SMC semi-finished products with more than two resin preparation layers can also be produced. It may also belong to several fiber layers if necessary. This does not only apply to contours 33 . 34 but also advantageously for the amount of fibers 6 , which optimizes to the flow zones of the SMC semi-finished product can be introduced and also helpful are undoswetted fiber bales in a molding 21 to prevent.

4 shows a schematic side view of a blank mat 18 , according to a contour rat section 32 to 3 passing through the transfer device 19 into a tool 35 a molding press 20 (not shown in the figure) is introduced. The blanket mat 18 can now with their adjusted contour, which in simplified representation on the corresponding tool 35 is tuned to a molding 21 be pressed.

5 shows a schematic plan view of a scrim 36 from several blanket mats 18 based on the contour rat sections 32 . 32 ' . 32 '' have different contours for pressing and folded together by means of the transfer device 19 into a tool 35 a molding press 20 be inserted and pressed there. It is not mandatory that the contour rat sections 32 . 32 ' . 32 '' be produced in the same order. It can be provided, for example, that between Konturmattenabschnitt 32 ' and 32 '' still a contour rat section 32X is produced in another molding press 20 ' or in another clutch 36 for another molding press 20 ' . 20 '' Use finds.

In 6 is shown in a highly macroscopic and schematic representation of a control and / or regulating device with a minimum necessary connection of the individual parts of the system for carrying out a conceivable method for operating such a system. In this case, at least one control device 26 with at least one of the following system components operatively connected control and / or control technology: at least one molding press 20 . 20 ' . 20 '' ..., a transfer device 19 and the flat railway system 16 with a mixing device 1 , a walk and drinker 15 , a thickening device 25 as a production device for creating an endless resin mats 10 by means of a cutting device 17 to the blanking mat 18 is cut to length. With regard to control and regulation technical terms should be noted that the control devices preferably consists of a programmable universal computer, the tasks of the control and regulation alternately by special interfaces with the individual system parts by suitable control technology and sensors for feedback of actual and comparison with setpoints or simultaneously must perform, in particular dependent on which part of the plant the control or regulatory strand is connected. To illustrate a control variable, for setting the Eindickstrecke C, this is only with a simple arrow with the thickening device 25 This does not rule out that feedback on the state and corresponding regulations for the exact adjustment of the thickening distance C are or are deemed necessary via sensors. The diagram also shows the relationship like the resin mats 10 in the mixing device 1 and the walk and drinker 14 prepared, preferably seamless in the thickening device 25 transferred to the variable Eindickstrecke C, matured there and then after the cut to the transfer device 19 for transporting the created blanking mats 18 in the appropriate molding press 20 . 20 ' . 20 '' ... is handed over.

7 shows an exemplary representation of a differentiated contour 40 with different heights h across the width b of a resin mat 10 on average. These variants would also be adjustable, but require some extra effort in terms of an adjustable doctor blade 4 . 7 , This shows 9 Example additional squeegee slider 13 , at the over the width of the basic height of the resin batch adjustable squeegee 4 are arranged and partially restrain or release over the width of a discharge. With this variant, it is possible, in particular, to generate traces of higher or lower material content on a resin layer.

8th shows an extension of a possible installation by an application device for introducing reinforcement areas 39 on a resin formulation layer 5 a resin mat to be produced, wherein the upper resin attachment layer 8th not shown. By means of a suitable applicator 38 preferably at least one cross-beam above the belt 2 arranged and movable by means of at least one linear conveying direction in at least one direction are gain areas 39 in a resin mat 10 trained and thereby selectively stored so that these in a Konturmattenabschnitt 32 and later in the corresponding blanket mat 18 perfectly fitting to the corresponding tool 35 a molding press 20 are arranged. Another reinforcing section is characterized by a partial elevation across the width by an increased Harzansatzaustrag from the doctor blade 4 formed and presents itself as a continuous reinforcing area. A second application device 38 is arranged stationarily and can at intervals reinforcing areas, fiber and / or resin filler material, carry out. In 10 is a collection of exemplary output devices, or better, applicator devices 38 for applying reinforcing means for introducing reinforcing regions into a resin mat to be produced. In the direction of production is first on the left side of a width adjustable fiber feeder, due to a rather narrow width of the lower resin formulation layer 5 the two outer discharge areas deactivated and only by means of the inner four Austragsbereiche (shown hatched) from at least one endless fiber roller 46 unwrapped continuous fibers either directly or disassembled on the resin formulation layer hangs up. In production direction further there is a more sophisticated design of an applicator 38 on two crossbeams with a linear conveyor 45 , A reinforcement area 39 formed from a nonwoven fabric 43 or an equivalent conglomerate, is already found on the resin batch and is passed through an industrial robot 42 and a gripper arranged thereon supplied from outside and stored according to the specifications at a defined location of a contour section. The fiber fleece 43 For this purpose, for example, can be punched or cut out of an endless roll and is preferably delivered on an intermediate conveyor. The intermediate conveyor device can also, for example, between an illustrated applicator 38 for a gain area 39 be arranged so that the applicator 38 For example, create a complicated contour on an intermediate conveyor, preferably a transfer belt from an endless conveyor belt, which is then deposited by simply by a movement of the transfer belt on the resin base layer. Finally, there is a sliver guide roller as a further embodiment of a discharge device 48 holding a sliver 47 from a roll and a slitting device 49 supplies. In conjunction with a cutting device, not shown (cutting blade) can also hereby a local gain range 39 to be created.

It can be stated that the pictorial representation only serves the understanding and is in parts deficient in relation to the reality. It is understandable that a set contour in length, width and height through the Walk and Drinking B is quite "verwalkt" and accordingly no longer realizes the sharpness of the original settings. In particular, the possibility of causing jagged contour changes by a short-term stop of the mixing device helps to defuse this problem. Nevertheless, it is possible to realize the setting of the contours according to the invention and to use. In particular, it is advantageous if the system can be controlled by a universal computer, which performs the tasks of a conventional control and / or regulating device. In this device, therefore, the local coincidence of the adjustable lower resin approach layer 5 from the squeegee 4 with the order of the fibers 6 from the fiber feeder 28 and / or the applicator 38 and with the upper resin attachment layer 8th from the squeegee 7 controlled. At the same time, a path-time tracking of the resulting resin mat is ensured, for example via time or path-dependent control, to ensure that the resin mat 10 is produced such that the produced Konturmattenabschnitte 32 easily after the mixing device 1 can be cut to the required blanking mats for one or more tools or scrim and significant outlines meet what is necessary. For a simplified path / time tracing, prior to combining the two resin attachment layers, a geometric feature or other suitable marker may be placed on at least one of the resin attachment layers, preferably in the exterior, to define the separation line of two contour rat sections therewith and to separate the separation section by means of a suitable recognition device through the cutting device 17 to lay exactly. A suitable marking may be a bar code on a film or other suitable marking, for example a piece of film which is automatically removed again by the trimming device or a color marking on the surface of the resin batch. Color markings could be performed with fluoszierenden means that are recognizable only under special lighting and preferably lose their fluorescence by an increase in temperature in the mold of the molding press. It would also be conceivable in the preparation of the resin attachment layers to incorporate ridges or countersinks that can be identified by the recognition device and activate the trimming device.

LIST OF REFERENCE NUMBERS

1

mixing device

2

Band below

3

Tape above

4

Lower squeegee

5

Resin batch layer

6

fibers

7

Upper squeegee

8th

Resin batch layer

9

resin batch

10

prepreg

11

Rolling, down

12

Rolling, top

13

squeegee slide

14

Walk and drinker

15

film take-off

16

Flat rail system

17

cutting device

18

cutting mat

19

Transfer device

20

molding press

21

molding

22

idler pulley

23

exit point

24

heater

25

thickening

26

control device

27

Long side of 10

28

fiber feeding

29

Sidewall movable

30

locking device 29

31

locking device 4

32

Contour rat section (endless)

33

Contour of height h along

34

Contour of width b

35

Tool in 20

36

scrim

37

crossbeam

38

applicator

39

gain regions

40

Contour of height h across

41

locking device

42

industrial robots

43

non-woven fabric

44

grab

45

Linear conveyor (b / s)

46

Continuous fiber roll

47

sliver

48

Sliver leadership

49

Slitter

A

Harzansatzaufbringstrecke

B

Walk and drinking track

C

Eindickstrecke

b

Wide resin mat 10

H

Height resin mat 10

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 1386721 A1 [0003, 0003]

Claims (24)

Process for producing fiber-reinforced molded parts (SMC) by means of extrusion in a molding press ( 20 ), an associated flat belt system ( 16 ) for the continuous production of an endless fiber-reinforced resin mat ( 10 ) and a transfer device ( 19 ) in the direct process, wherein in the flat belt plant ( 16 ) in a mixing device ( 1 ) at least one resin formulation layer ( 5 . 8th ) with fibers ( 6 ), in a subsequent Walk and impregnation device ( 14 ) and finally in a thickening device ( 25 ) to an endless resin mat ( 10 ) and the endless resin mat ( 10 ) to cut mats ( 18 ) and subsequently direct or to a clutch ( 36 ) with further blanking mats ( 18 ) merged by means of the transfer device ( 19 ) into a tool ( 35 ) a molding press ( 20 ) and in the molding press ( 20 ) to a fiber-reinforced molded part ( 21 ) is pressed, characterized in that by means of at least one transfer device ( 19 ) at least two molding presses ( 20 . 20 ' ) with the in a flat belt system ( 16 ) and to finite cut mats ( 18 ) divided endless resin mat ( 10 ). Method according to claim 1, characterized in that the molding presses ( 20 . 20 ' ) are fed alternately. Method according to claim 1 or 2, characterized in that when using different tools ( 35 ) with different pressing times the molding presses ( 20 . 20 ' ) are fed sequentially as needed. Method according to one or more of the preceding claims, characterized in that the blanking mats ( 18 ) with at least one variable contour ( 33 . 34 . 40 ) at the height (h) in and / or transversely to the production direction and / or an endless resin mat (a) having a different width (b) ( 10 ) and / or the width and / or amount of fibers ( 6 ) by means of at least one fiber feed device ( 28 ) are discharged differently in and / or transversely to the direction of production and / or in different widths (b). Method according to one or more of the preceding claims, characterized in that for the production of a lengthwise and / or in width opposite at least one resin formulation layer ( 5 . 8th ) limited gain range ( 39 ) prior to combining the resin attachment layers ( 5 . 8th ) Means for reinforcement on at least one resin attachment layer ( 5 . 8th ) are applied. Method according to one or more of the preceding claims, characterized in that as reinforcement means for the reinforcement region ( 39 ) a resin batch and / or at least one short fiber, a long fiber, chopped glass, an endless fiber, a single fiber, a sliver ( 47 ) (Fiber tape), a fiber fabric, a nonwoven fabric ( 43 ) and / or a composite conglomerate of these ingredients. Method according to one or more of the preceding claims, characterized in that the reinforcing regions and / or the contours ( 33 . 34 . 40 ) a topographical pattern in the resin mat ( 10 ) and that this pattern after cutting into a blank mat ( 18 ) with the topography of a part of a jig for a tool ( 35 ) or with a tool itself substantially or proportionally. Method according to one or more of the preceding claims, characterized in that the means for amplifying or for forming the amplification area ( 39 ) by means of an applicator device ( 38 ) directly on the resin formulation layer ( 5 . 8th ) and / or prefabricated by means of an intermediate conveying device on the resin formulation layer ( 5 . 8th ) and / or directly during the Aufrakelung the Harzansatzschicht ( 5 . 8th ) to be created. Method according to one or more of the preceding claims, characterized in that the amplification area ( 39 ) in its arrangement on one of the resin mat ( 10 ) to be cut blank mat ( 18 ) is selected such that this with a corresponding geometry of the tool ( 35 ) of the molding press ( 20 ) or part of a jig for a tool ( 35 ) matches. Method according to one or more of the preceding claims, characterized in that from the resin preparation layers ( 5 . 8th ) respectively from the endless resin mat ( 10 ) Contour rat sections ( 32 ), the length of the cut mats (in their length 18 ) for a tool ( 35 ) or part of a case ( 36 ) and at least proportional to the tool ( 35 ) and / or the clutch ( 36 ) and / or the molded part ( 21 ) are tuned. Method according to one or more of the preceding claims, characterized in that for setting at least one contour ( 33 . 34 . 40 ) the control device ( 26 ) at least one adjusting device ( 30 ) for adjusting the width (b) of a doctor blade ( 4 . 7 ) and / or the control device ( 26 ) at least one adjusting device ( 31 ) for at least partial adjustment of the height (h) on a doctor blade ( 4 . 7 ) and / or the control device ( 26 ) the Fiber feeder ( 28 ) for adjusting the width and / or the amount of fibers ( 6 ). Method according to one or more of the preceding claims, characterized in that a plurality of successive contour rat sections ( 32 . 32 ' . 32 '' , ...) of the same or different contours ( 33 . 34 . 40 ) to a clutch ( 36 ) and in a tool ( 35 ) a molding press ( 20 ) to a molded part ( 21 ) are pressed. Method according to one or more of the preceding claims, characterized in that the means for reinforcing prior to the application to a resin formulation layer ( 5 . 8th ) are at least partially impregnated with resin and / or oriented. Plant for the production of fiber-reinforced molded parts (SMC) by extrusion in a molding press ( 20 ) from one in a flat belt system ( 16 ) continuously produced fiber-reinforced resin mat ( 10 ), wherein in the flat belt system ( 16 ) a mixing device ( 1 ) for combining at least one resin formulation layer ( 5 . 8th ) with fibers ( 6 ), a subsequent Walk and soak device ( 14 ) for mixing and a thickening device ( 25 ) for maturing the endless resin mat ( 10 ) is arranged, wherein for cutting the endless resin mat ( 10 ) to a blank mat ( 18 ) a cutting unit ( 17 ), for the transfer of the blank mat ( 18 ) to the molding press ( 20 ) a transfer device ( 19 ) and for pressing the blank mat ( 18 ) to a fiber-reinforced molded part ( 21 ) a molding press ( 20 ) is arranged, characterized in that in the plant for pressing in the flat belt plant ( 16 ) and to finite cut mats ( 18 ) divided endless resin mat ( 10 ) at least two molding presses ( 20 . 20 ' ) are arranged. Plant according to claim 14, characterized in that in the plant a flat web plant ( 16 ) for the production of SMC mats with at least one differentiated contour ( 33 . 34 . 40 ) and / or with amplification areas ( 39 ) are arranged. Plant according to claim 14, characterized in that the flat track system ( 16 ) upstream of the merge area of two resin formulation layers ( 5 . 8th ) for forming a resin mat ( 10 ) for creating at least one reinforcement region ( 39 ) at least one application device ( 38 ) for depositing means for reinforcement and / or at least one width-adjustable doctor blade ( 4 . 7 ) for the preparation of means for reinforcement on a resin formulation layer ( 5 . 8th ) is arranged. Plant according to claim 14, characterized in that the flat track system ( 16 ) for storing reinforcing means for the reinforcing region ( 39 ) an application device ( 38 ), which is suitable for depositing a resin batch and / or at least one short fiber, a long fiber, chopped glass, an endless fiber, a single fiber, a sliver ( 47 ) (Fiber tape), a fiber fabric, a non-woven fabric ( 43 ) and / or a composite conglomerate of these components. Plant according to one or more of the preceding claims 14 to 17, characterized in that in the flat web plant ( 16 ) the application device ( 38 ) for the reinforcement means on a cross-beam ( 37 ) across the width of a resin formulation layer ( 5 . 8th ) by means of at least one linear conveyor device ( 45 ) across the width and / or the direction of production and / or at a distance from the resin formulation layer ( 5 . 8th ) is arranged movable. Installation according to one or more of the preceding claims 14 to 18, characterized in that in the flat track system ( 16 ) as an application device ( 38 ) for the means of reinforcing an industrial robot ( 42 ) or a transfer device with a gripper ( 44 ) and / or a transfer belt and / or at least one nozzle for the resin batch and / or a scattering device for fibers ( 6 ) is arranged. Installation according to one or more of the preceding claims 14 to 19, characterized in that in the flat track system ( 16 ) for producing a variable contour ( 33 . 34 . 40 ) for forming a gain region ( 39 ) in height (h) and / or width (b) in an endless resin mat ( 10 ) at least one adjusting device ( 31 ) for setting different heights (h) and / or at least one adjusting device ( 29 ) for setting different widths (b) on at least one doctor blade ( 4 . 7 ) are arranged. Installation according to one or more of the preceding claims 14 to 20, characterized in that measuring and / or adjusting devices for a path and / or time tracking of the contours ( 33 . 34 . 40 ) for the control device ( 26 ) are arranged. Plant according to one or more of the preceding claims 14 to 21, characterized in that the control device ( 26 ) is operatively connected to at least one of the following parts of the plant: at least one forming press ( 20 . 20 ' ), a transfer device ( 19 ), a flat belt system ( 16 ) for creating an endless resin mat ( 10 ). Resin mats for use in at least two molding presses ( 20 ) in the course of the production of Molded parts ( 21 ), in particular produced by the process according to claim 1 and / or in particular produced in a plant according to claim 14, characterized in that in a flat belt plant ( 16 ) resin mat ( 10 ) in their height (h) and / or across their width (b) a differentiated contour ( 33 . 34 . 40 ) and / or at least one reinforcing region consisting of means for amplification ( 39 ) based on one of the two molding presses ( 20 . 20 ' ) having. Resin mat according to claim 17, characterized in that the resin mat ( 10 ) in at least one contour ( 33 . 34 . 40 ) and / or at least one amplification area ( 39 ) to a tool ( 35 ) or at least to a part of a tool ( 35 ) in a molding press ( 20 ) is adjusted.

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