DE102010019625B4 - Method for producing a composite or hybrid construction - Google Patents

Abstract

A method for producing a composite or hybrid construction (50) comprising at least one thermoplastic component using an injection molding machine (1) having at least one insert (6, 6 '), the injection molding machine (1) having two parting planes (A, B, C) , characterized in that in one of the parting planes (A, B, C) a structural element (53) is deformed by hydroforming based on water pressure and in the other parting plane (A, B, C) is over-molded with plastic.

Description

The invention relates to a method for producing a composite or hybrid construction comprising at least one thermoplastic plastic component.

For the production of composite structures or composite materials but also for the production of hybrid constructions, different methods are known in the prior art. In composite materials, different materials are joined by fabric or form-fitting, or a combination of both. Worth mentioning are, for example, fiber composites, in which fiber fabric or knitted fabric are mixed with plastic in order to obtain in the end a composite construction which has improved properties. Hybrid designs combine systems with different technologies. Very often these are plastic / metal hybrids that combine the advantages of plastic and metal.

From the prior art known methods for the production of composite or hybrid constructions are usually multi-stage, resulting in a high cost and labor.

The DE 20 2005 021 394 U1 discloses an apparatus for the manufacture of complex parts, in particular assembly injection molding of multi-part products. This is achieved with the use of an injection molding machine, in which the individual parts are produced in the region of different parting planes, then brought by means of a turning plate in the region of a further parting plane and there operatively connected.

The DE 10 2008 046 908 A1 discloses a method for producing plastic products with partially provided structures, as well as an apparatus for carrying out the method. The method makes it possible to produce a plastic base body, to bring a structure of fibers on it and to mold the structure into the overall plastic product by applying a further plastic material. Transporting from one process step to the next takes place by means of a turning plate.

The DE 10 2006 026 063 A1 discloses a method of making coated plastic moldings, and a device therefor. The disclosure provides that the preparation or the preliminary work and the actual spraying of the plastic compound take place in separate working levels. In the first working levels, a web material is deformed between two mold halves, also by means of compressed air and / or vacuum; The deformed web material is then positioned in a second working plane by means of a turning plate and is molded there with plasticized plastic compound. At the end, the composite plastic material is removed from the device.

The DE 199 49 263 A1 discloses a method for manufacturing plastic components in a single tool unit. First, a flat basic shape is separated from a flat semi-finished product, then this basic shape is heated and ultimately the heated basic shape is embossed into the desired shape and removed after a cooling phase of the tool unit. The DE 199 49 263 A1 also discloses a method which excels in cutting the basic shape from a sheet of sheet material and transporting the basic shape to the other process steps by means of a turning device.

The DE 102 27 636 A1 discloses a method for producing multi-component plastic molded parts. In a first step, fiber material is deformed in a mold located in a first working plane. The preform is then transported by means of a rotating device to a second working plane and encapsulated here with plastic or injection molded from plastic.

The DE 10 2006 016 200 A1 discloses a method and an apparatus for producing multi-component plastic molded parts. The method provides that various mold halves are disposed on a rotatable plate and that they cooperate with the mold halves disposed on the body of the injection molding machine to form cavities. In a first step, preforms are produced; the turntable is then rotated and the preforms produced in the first step of the process are provided with a further component.

Object of the present invention is therefore to provide a method of the type mentioned, in which the workload and consequently the cost is reduced.

This object is achieved by a method of the type mentioned, which is characterized by the use of an injection molding machine with at least one insert, according to the features of claim 1.

The use of an injection molding machine with at least one insert makes it possible to combine several process steps on the injection molding machine, so that different process steps can be quickly combined on the spot.

In one embodiment, it may be provided that are injected using an injection molding machine with at least two inserts and at least three injection stations through the first and second injection station two moldings, which are directed to one another after rotation of the inserts and interconnected by the third injection station. The use of two inserts and three injection stations makes it possible not only to quickly produce the individual molded parts, but also to connect them together in an immediately subsequent step. It can be provided that in one of the injection stations, a structural element, preferably a functional element and / or a reinforcing structure is prepositioned. In the preferred case, it is then provided that the structural element, preferably a functional element and / or a reinforcing structure, is positioned after turning the inserts and before joining the two moldings between the two moldings.

From a procedural economic point of view, it is advantageous if, after the turning of the inserts, and preferably simultaneously with the joining of the already molded parts, new moldings are injected in the first and second injection stations.

In another embodiment, it can be provided that, using an injection molding machine with at least one insert and at least one injection station in a parting plane between the insert and another platen a structural element, such as a fiber fabric, fiber fabric, prepreg or combinations thereof, inserted and after Turning the insert is over-injected in the injection station. It can further be provided that the structural element - is preformed in the injection molding machine - before over-molding. Furthermore, alternatively or additionally, it may be provided that the structural element is preheated in the injection molding machine before overmolding.

In a further embodiment of the invention can be provided that the structural element is over-injected either by using a further injection station or by turning the insert on both sides.

In one embodiment, it can be provided that the structural element is punched by merging the insert and another platen and / or a punch in the injection molding machine. The punching operation can either be performed by a mold or a part of the mold or be made by an additionally provided punching tool. However, such a punching tool can also interact with a part of the molding tool so that punching tool and molding tool jointly perform the punching operation.

In a further embodiment, it can be provided that the structural element is introduced onto a foil backing in the injection molding machine. In all embodiments it can be provided that the injection molding machine has two parting planes and in one of the parting planes a structural element is preferably deformed by water pressure and oversprayed with plastic in the other parting plane.

In addition, it can be provided that the injection molding machine has at least one insert with two parting planes, wherein each of the parting planes an extruder and a plasticizing and injection unit are assigned, so that the production of the composite and / or hybrid construction takes place by direct compounding.

Furthermore, it can be provided that the injection molding machine has at least one turning plate in the form of a rotary cube with four staggered by 90 ° stations. Two of the stations can be designed as injection stations and in a station, a structural element can be supplied by a handling device. In a station can be provided that a station is designed as a removal station or ejection station. In a further embodiment, it can be provided that the production of the composite or hybrid construction takes place at least partially by in-situ polymerization of at least one monomer in a cavity of the injection molding machine, wherein pressure buildup in the cavity takes place by reducing the size of the cavity when the polymerization starts. Furthermore, it can be provided that the production of the composite or hybrid construction takes place at least partially by applying a lacquer layer. For example, PUR has proved to be advantageous as in-situ polymers and / or as coating layers to be applied.

The molded parts produced in the intermediate steps are preferably half-shells.

In general, it has proved to be advantageous if the structural element ( 53 ) is selected from the group fiber fabrics. Fiber fabric, prepreg or combinations thereof. It is advantageously provided that the fibers of the fiber fabric and / or fiber fabric are selected from the group of glass fibers, basalt fibers, carbon fibers or mixtures thereof.

Further details and advantages of the invention will be explained with reference to the following figures and description of the figures.

It shows

1 an injection molding machine for carrying out the method according to the invention,

2a and 2 B a variant embodiment for carrying out the method using two inserts and the resulting composite structures or hybrid constructions,

3a and 3b a variant embodiment for carrying out the method using a turning insert and with a preforming and the resulting composite and hybrid constructions,

4 a variant embodiment for carrying out the method using a turning plate, wherein a structural element is preheated,

5 two method steps for carrying out the method using a turning plate and a punching tool,

6a and 6b two method steps of a variant embodiment for carrying out the method using a turning plate and two L-shaped plasticizing and injection units,

7a and 7b a variant embodiment for carrying out the method using two inserts and a punching tool,

8a and 8b an embodiment variant for carrying out the method using a turning plate, wherein a Fluiddruckvorformung is provided

9a and 9b a variant embodiment for carrying out the method according to the invention using a turning plate and a plurality of extruders and the resulting composite or hybrid constructions,

10 a variant for carrying out the method using a turning plate in the form of a rotary cube,

11a and 11b a last embodiment variant for carrying out the method according to the invention using a turning plate and a feeding device of a monomer and the composite or hybrid constructions produced therefrom.

In the 1 is an injection molding machine 1 shown, which can be used for the inventive method. The injection molding machine 1 has a closing unit in a known manner 2 as well as a plasticizing and injection unit 3 on. The closing unit 2 includes a fixed platen 4 on a frame 9 is arranged fixed. Furthermore, a movable platen 5 provided on a slide shoe 7 on a for example in 2a shown slide rail 31 linear along the columns 10 is movable. The movement of the movable platen 5 done by a driving cylinder 16 with a piston-cylinder unit 15 from and to the fixed platen 4 , For fixing the movable platen 5 in the desired position on the columns 10 are locking mechanisms 14 provided, the positive and / or frictional, the movable platen 5 at the columns 10 fix. Furthermore, a turning plate 6 provided on a slide shoe 8th linear between the movable platen 5 and the fixed platen 4 is mobile. The insert 6 is on a slide shoe 8th in a slide rail 31 arranged. Furthermore, a driving cylinder 16 comprising a piston-cylinder unit for linear movement along the columns 10 from and to the fixed platen 4 intended. The insert 6 additionally has a turntable 61 as a turntable, so that rotation along the axis of rotation a can take place. The mold clamping plates 4 . 5 as well as the insert 6 are on a frame 9 arranged. There are also pressure pads 13 for storage of the fixed platen 4 intended. The closing unit 2 has the parting planes A and B.

The plasticizing and injection unit 3 is also constructed as known per se, so that will be discussed here only briefly. Via a hopper 17 can plastic granulate in the plasticizing cylinder 18 be transported, where a plasticizing screw is arranged, which plasticizes the plastic granules. About a nozzle 23 and an injection movement can plasticized plastic in the mold 11 be injected. For the plastification and the subsequent injection is a drive unit 24 provided, which puts the plasticizing screw on the one hand in rotational movement and on the other hand performs a linear movement for injection. The drive unit 24 can, as known per se, for example, be designed hydraulically. The plasticizing and injection unit 3 is on a frame 19 arranged. At the movable platen 5 is another plasticizing and injection unit 20 intended. This is on a frame 22 arranged with the fixed platen 4 connected is. During a movement of the movable platen 5 from or to the fixed platen 4 do that Plasticizing and injection unit 20 this movement with. The plasticizing and injection unit 20 also has a hopper 21 for plastic granules and a plasticizing unit 25 , which also forms an injection unit at the same time. About a nozzle 26 can in the mold 12 plasticized plastic are injected.

In the embodiment shown are two molds 11 . 12 recognizable, each of two mold halves 11 ' . 11 '' respectively. 12 ' . 12 '' be formed. Due to the relative movement of movable platen 5 , Insert 6 along the columns 10 towards the fixed platen 4 (or away from this), close the respective mold halves 11 ' . 11 '' respectively. 12 ' . 12 '' and form the molding space for the thermoplastic resin component injected in the plasticized state. It can first in the first closed mold 11 be injected, then after opening the mold 12 the insert 6 rotated about the rotation axis a by 180 °, so that the mold half 11 '' in the picture plane now to the position of the former form half 12 ' to come to rest. By closing the mold now grip the mold halves 11 '' and 12 '' into each other and form a new shape, it being anticipated that the molding formed in the first cycle will be on the mold half 11 '' is arranged and introduced into the new mold. Then can on the plasticizing and injection unit 20 another thermoplastic resin component is injected and the finished composite or hybrid construction 50 be formed. Furthermore, before one of the two injections in one of the two molds 11 . 12 a structural element are introduced. Of course, in the molds 11 and 12 be injected at the same time. It is therefore intended that after turning the insert 6 at the same time moldings are injected. The plasticizing and injection unit 3 and the mold 11 form an injection station and the plasticizing and injection unit 20 with the mold 12 form another injection station.

In the 2a a variant is shown, which is essentially the example of 1 corresponds, only that now at the clamping unit 2 next to the fixed platen 4 and the movable platen 5 a first insert 6 and a second insert 6 ' on the slide rail 31 are arranged linearly movable. In this embodiment, three parting planes A, B, C are provided. In addition, a third plasticizing and injection unit 30 provided, which is approximately L-shaped to the first plasticizing and injection unit or to the second plasticizing and injection unit 20 is arranged. The plasticizing and injection unit 30 is on the insert 6 arranged and makes their movements with. For the sake of clarity, attention was drawn to the marking of the remaining components on the clamping unit 2 as well as on the plasticizing and injection units 3 . 20 and 30 waived.

It should be noted at this point that the reference numbers in all figures coincide, so that it is omitted to explain each reference number again for each figure. Reference is made to the respective preceding description of the figures.

In a first process step, the individual mold platens 4 . 5 and inserts 6 . 6 ' move each other so that the molds 11 . 12 . 121 (formed by the mold halves 11 ' . 11 '' . 12 ' . 12 '' . 121 ' . 121 '' ) are closed and form the desired shape. On the side of the mold 11 is via the plasticizing and injection unit 3 injected plasticized thermoplastic component, so that subsequently the molding 51 in the form of a half-shell (see 2 B ) is formed. At the same time can be on the mold 12 via the plasticizing and injection unit 20 the molding 52 be formed. After the molding of the moldings 51 . 52 become the individual molding tools 11 . 12 . 121 by moving apart of the individual plates (platen 5 and inserts 6 . 6 ' open with the molding 51 on the mold half 11 '' and the molding 52 on the mold half 12 '' remains. Subsequently, the inserts are 6 . 6 ' rotated along its axes of rotation a, b by 180 °, so that in the middle of the mold halves 12 ' and 11 '' are directed towards each other. About a handling device 60 can be a structural element 53 be inserted into the newly emerging form. Subsequently, the individual molds are closed again and one on the insert 6 firmly arranged plasticizing and injection unit 30 is over the line 31 Plastic in the new form, formed from the mold halves 11 '' and 12 ' , injected, so that the moldings 51 . 52 be connected to each other. The structural element 53 becomes simultaneously with the moldings 51 . 52 connected. As a structural element 53 In the case shown, a functional element, such as an antenna (but also a transponder, RFID, etc.) is conceivable. By opening the molds, the finished composite or hybrid construction 50 be removed.

In the 3a now forms the mold 12 at the same time a preforming unit, the structural element 53 that with a handling device 60 is inserted, by the applied pressure and optionally temperature increase to the preform 56 preforming. After opening the molds, turn the insert 6 around the axis of rotation a, that can be in the mold half 12 ' remaining preform are inserted into the newly formed mold and then with thermoplastic plastic component from the plasticizing and injection unit 3 be sprayed.

The 4 now shows a variant with only one insert 6 and only one plasticizing and injection unit 3 , In the open state is via the handling device 60 a structural element 53 in the mold 12 to the mold half 12 '' placed. The mold 12 has a heater 70 on that the structural element 53 heated in advance. At the structural element 53 in the preferred case it is a so-called prepreg (sometimes referred to as organo-sheet). In the preferred case, this is a fiber-reinforced plastic, for example glass-fiber-reinforced thermoplastic. The structural element 53 thus forms an insert in the form of a reinforcing structure. In the concrete case, it is the structural element 53 around a prepreg, with fiberglass reinforced plastic in the mold 12 inserted and with the heater 70 is heated, so that the plastic softens. The heating takes place in a closed mold 12 , After heating and optional embossing inside the mold 12 becomes the mold 12 opened again, the insert 6 rotated, the structural element 53 in the heated state on the mold half 12 ' and when closing with the mold half 11 ' forms a new mold. Then you can use the injection and plasticizing unit 3 plasticized plastic in the mold formed by the mold halves 11 ' . 12 ' be injected and a corresponding composite or hybrid construction 50 be generated.

In the 5 is shown a further embodiment in which a structural element 53 is introduced, in which a material web 53 ' by means of a punching tool 71 that at a tab 72 the mold half 12 '' so engages that part of the web 53 ' is punched out. The punching tool 71 so far about the mold half 12 '' until it rests against the stop of the projection. The structural element 53 is doing of the material web 53 ' separated and into the mold 12 transferred. After opening the mold, the insert is 6 rotated, transferred to the right position of the image plane and after closing the mold by engagement of the mold halves 12 ' and 11 ' enclosed in the resulting mold. About the plasticizing and injection unit 3 Finally, thermoplastic resin component is injected into this mold and the finished composite or hybrid construction 50 generated.

The 6a and 6b show an embodiment of the 4 very similar variant, again with a structural element 53 via a handling device 60 in the mold 12 is used. This can be from one side via the plasticizing and injection unit 30 attached to the insert 6 is arranged to be molded with thermoplastic component. This is in the 6b shown. After opening the mold 12 , Turning the insert 6 and re-closing can be done via the plasticizing and injection unit 3 the second side of the molding 51 be sprayed. The generated composite or hybrid construction 50 is shown in the lower right illustration, with two outer moldings 51 . 52 in the form of plastic layers and an intervening structural element 53 can be seen in the form of an insert layer. Again, the structural element may be a prepreg or other materials.

The 7a shows a combination of the variants of the 5 and 6a and 6b , wherein first of a material web 53 ' a structural element 53 with a punching tool 71 is punched out and into the first mold 12 is introduced. After turning the first insert 6 ' can via the plasticizing and injection unit 30 one side of the structural element 53 be sprayed. After reopening the mold, turn the insert 6 and closing the mold can via the plasticizing and injection unit 3 also the second side of the structural element 53 to be overmoulded.

The 8a and 8b show a further embodiment variant for carrying out the method. In this case, in a first mold via a handling device 60 a structural element 53 introduced. About so-called hydroforming in the mold can via a fluid in the 8b shown left form of the structural element 53 be generated. After turning the insert 6 , re-closing and injecting via the plasticizing and injection unit 3 , can the finished composite or hybrid construction 50 according to right picture of the 8b be generated.

In the 9a and 9b a variant of the invention is shown in which in addition to the plasticizing and injection unit 3 and the plasticizing and injection unit 20 additionally extruder 99 . 99 ' are provided. These serve to enable direct compounding. It is about the plasticizing and injection unit 3 conventional thermoplastic plastic component plasticized and / or additionally via the extruder 99 plasticized another thermoplastic resin component with additional components. This is in the plasticizing the plasticizing and injection unit 3 transported after closing the mold 11 performs an injection process. The same applies to the plasticizing and injection unit 20 and its associated extruder 99 ' , The production of composite or hybrid construction 50 (possibly also with structural element 53 ) takes place analogously to the description 1 , In addition, a shotpot, not shown, may be provided to allow the extruder 99 . 99 ' also during injection through the plasticizing and injection units 3 . 20 can plasticize.

In the 10 a variant is shown, with a turning plate 6 , in the form of a rotary cube, wherein the axis of rotation a is horizontal, that is normal to the plane of representation, wherein the rotary cube has four positions or stations I, II, III, IV, which are separated by 90 ° from each other. But just as well can be provided that the rotation axis a is arranged vertically as in the previous examples. For the sake of clarity, however, the in 10 shown representation, as the individual stations I, II, II ', IV are better visible. The first station I describes an injection molding process for a first molded part in the form of a half shell. After opening the mold, the insert is rotated 90 ° and a handling device 60 a structural element 53 in the mold half 11 ' brought (Station II). After another 90 ° turn (station III), the mold is closed again and thermoplastic components via the plasticizing and injection unit 20 injected. After reopening the mold and rotating the rotary cube by 90 °, the finished composite or hybrid construction can be removed via a removal station (Station IV). This is a ejection station.

The variants of the 11a and 11b differ from the embodiment of 1 only in that in addition to the plasticizing and injection unit 20 additionally one unit 93 is intended for insertion of still polymerizing plastic. In this case, at least one monomer is introduced into the cavity and polymerized in the cavity. At the start of the polymerization, an increased pressure in the cavity is built up by reducing the size of the cavity. Here, for example, a thin Lackschnicht 52 z. B. a PUR paint can be applied. Alternatively, via the plasticizing and injection unit 20 also thermoplastic plastic component can be introduced. Preferably, the thermoplastic resin component is applied as a thin layer, for example by injection-compression molding.

In the embodiments except the 10 it can be provided that the axis of rotation (s) a, b of the insert (s) 6 . 6 ' not vertical but also horizontal (as in 10 ) is (are) arranged.

LIST OF REFERENCE NUMBERS

1

injection molding machine

2

closing unit

3, 20, 30

Plasticizing and injection unit

4

fixed platen

5

movable platen

6, 6 '

insert

7, 8

shoe

9, 19, 22

frame

10

pillar

11, 12, 121

mold

11 ', 11' ', 12', 12 '', 121 ', 121' '

mold

13

caul

14

Verrieglungsmechanismen

15

Piston-cylinder unit

16

driving cylinder

17, 21

hopper

18

plasticizing

23

jet

24

drive unit

25

plasticizing

31

slide

50

hybrid construction

51, 52

molding

53

structural element

53 '

web

56

preform

60

handling device

61, 61 '

rotary unit

70

heater

71

punching tool

72

head Start

93

Unit for inserting still polymerizing plastic

99, 99 '

extruder

I, II, III, IV

Stations of the insert

A, B, C

separating planes

a, b

axis of rotation

Claims (15)

Method for producing a composite or hybrid construction ( 50 ) containing at least one thermoplastic component using an injection molding machine ( 1 ) with at least one insert ( 6 . 6 ' ), wherein the injection molding machine ( 1 ) has two parting planes (A, B, C), characterized in that in one of the parting planes (A, B, C) a structural element ( 53 ) on hydroforming based on Water pressure deformed and in the other parting plane (A, B, C) is over-injected with plastic. A method according to claim 1, characterized in that using an injection molding machine ( 1 ) with at least two inserts ( 6 . 6 ' ) and at least three injection stations through the first and second injection station two moldings ( 51 . 52 ), which after a rotation of the inserts ( 6 . 6 ' ) are aligned with each other and connected by the third injection station. A method according to claim 2, characterized in that in one of the injection stations, the structural element ( 53 ), preferably a functional element and / or a reinforcing structure, is pre-positioned. Method according to claim 3, characterized in that the structural element ( 53 ), preferably functional element and / or reinforcing structure, after turning the inserts ( 6 . 6 ' ) and before joining the two moldings ( 51 . 52 ) between the two mold parts ( 51 . 52 ) is positioned. A method according to claim 2 or 3, characterized in that after turning the inserts ( 6 . 6 ' ) and preferably simultaneously with the joining of the already molded parts ( 51 . 52 ), in the first and second injection station new moldings ( 51 . 52 ) are sprayed. A method according to claim 1, characterized in that using an injection molding machine ( 1 ) with at least one injection station in a parting plane (A, B, C) between the insert ( 6 . 6 ' ) and another mold clamping plate ( 4 . 5 ) the structural element ( 53 ), such as a fiber fabric. Fiber fabric, prepreg or combinations thereof, inserted and after turning the insert ( 6 . 6 ' ) is oversprayed in the injection station. Method according to claim 6, characterized in that the structural element ( 53 ) Is preformed in the injection molding machine before overmolding. Method according to claim 6 or 7, characterized in that the structural element ( 53 ) - before overmolding - in the injection molding machine ( 1 ) is preheated. Method according to one of claims 1 to 8, characterized in that the structural element ( 53 ) either by using another injection station or by turning the insert ( 6 . 6 ' ) is over-injected on both sides. Method according to one of claims 2 to 9, characterized in that the structural element ( 53 ), preferably a reinforcing structure, by merging the insert ( 6 . 6 ' ) and another mold clamping plate ( 4 . 5 ) and / or a punching tool ( 71 ) in the injection molding machine ( 1 ) is punched. Method according to one of claims 3 to 10, characterized in that the structural element ( 53 ) on a foil backing in the injection molding machine ( 1 ) is introduced. Method according to claim 1, characterized in that each of the parting planes (A, B, C) is an extruder ( 99 . 99 ' ) and a plasticizing and injection unit ( 3 . 20 ), so that the production of the composite or hybrid construction ( 50 ) by direct compounding. Method according to one of the preceding claims, characterized in that the production of the composite or hybrid construction ( 50 ) at least partially by in situ polymerization of at least one monomer in a cavity of the injection molding machine ( 1 ) takes place, wherein at the start of the polymerization, a pressure build-up in the cavity by reducing the cavity takes place. Method according to one of the preceding claims, characterized in that the production of the composite or hybrid construction ( 50 ) at least partially by applying a lacquer layer. A method according to claim 13 or 14, characterized in that the in situ polymer or the paint layer comprises PUR.

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