DE102012015715A1 - Method for manufacturing of sandwich panels of hybrid particle foam and cover layer, involves inserting pre-consolidated preform into mold, and injecting molten plastic into tool cavity, where particle foam spheres are filled in mold space - Google Patents

Method for manufacturing of sandwich panels of hybrid particle foam and cover layer, involves inserting pre-consolidated preform into mold, and injecting molten plastic into tool cavity, where particle foam spheres are filled in mold space Download PDF

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Publication number
DE102012015715A1
DE102012015715A1 DE201210015715 DE102012015715A DE102012015715A1 DE 102012015715 A1 DE102012015715 A1 DE 102012015715A1 DE 201210015715 DE201210015715 DE 201210015715 DE 102012015715 A DE102012015715 A DE 102012015715A DE 102012015715 A1 DE102012015715 A1 DE 102012015715A1
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DE
Germany
Prior art keywords
mold
particle foam
cover layer
preform
cavity
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
DE201210015715
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German (de)
Inventor
Anmelder Gleich
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
WOBBE, HANS, DR.-ING., DE
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Hans Wobbe
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Publication date
Application filed by Hans Wobbe filed Critical Hans Wobbe
Priority to DE201210015715 priority Critical patent/DE102012015715A1/en
Publication of DE102012015715A1 publication Critical patent/DE102012015715A1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/20—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored
    • B29C67/205—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored comprising surface fusion, and bonding of particles to form voids, e.g. sintering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
    • B29C44/146—Shaping the lining before foaming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum

Abstract

The method involves inserting a pre-consolidated preform into the mold and closing the mold, and injecting the molten plastic into the tool cavity. The holding pressure pressure phase comprises partial cooling of the top layer preform. The particle foam spheres are filled in the mold space by a tool movement established between the cover layer preform and the surface of the cavity of the mold tool. The particle foam spheres are sintered under pressure and temperature. The particle foam is cooled and stabilized.

Description

Die Erfindung betrifft ein Herstellverfahren für ein Sandwichbauteil, welches neben einer faserverstärkten Kunststoffschicht eine an diese anliegende Schaumschicht aus Partikelschaum aufweist. Üblicherweise werden zur Herstellung von Kunststoff-Sandwichbauteilen die Schaumkerne aus Partikelschaum separat in eigenen Fertigungsschritten hergestellt. Diese Kerne werden anschließend in einem weiteren Verarbeitungsschritt in Verbindung mit faserverstärkten Kunststoffen zu den sogenannten Sandwichbauteilen komplettiert.The invention relates to a manufacturing method for a sandwich component, which in addition to a fiber-reinforced plastic layer has a foam layer of particle foam applied to this. Usually, the foam cores made of particle foam are produced separately in their own production steps for the production of plastic sandwich components. These cores are then completed in a further processing step in conjunction with fiber-reinforced plastics to form the so-called sandwich components.

Aus der DE 100 24 814 A1 ist ein solches Verfahren generell bekannt, mit Bezug insbesondere auf Karosserieteile. Dabei handelt es sich jedoch um einen Schaumkern aus chemisch oder physikalisch geschäumten Kunststoffen. Zunächst wird dabei eine noch nicht mit einer Kunstharz-Matrix versehene Faserverstärkungsmatte in einem Hinterschäumwerkzeug hinterschäumt, wonach in die Faserverstärkungsmatte die Kunstharz-Matrix eingebracht wird.From the DE 100 24 814 A1 Such a method is generally known, with particular reference to body parts. However, this is a foam core of chemically or physically foamed plastics. In the process, a fiber reinforcement mat not yet provided with a synthetic resin matrix is first foamed back in a back foaming tool, after which the synthetic resin matrix is introduced into the fiber reinforcement mat.

Aus der EP 12 992 19 ist ein Verfahren zur Herstellung von Formteilen aus Partikelschaum mit einer Deckschicht bekannt, dessen Hauptanspruch sich darauf bezieht, dass in zeitlicher Reihenfolge der Formraum eines Werkzeugs erst mit dem Partikelschaum gefüllt und ausgeschäumt wird, danach die Deckschicht in flüssiger Phase zwischen das Vorformteil und das Formwerkzeug spritzgegossen wird. Bei dieser Verfahrenssequenz wird das Vorformteil aus Partikelschaum jedoch in dem Moment kollabieren – aufgrund zu hoher Temperaturdifferenz – in dem die schmelzflüssige Deckschicht auf den Vorformling einwirkt.From the EP 12 992 19 a method for the production of moldings made of particle foam with a cover layer is known whose main claim is that in time sequence of the mold cavity of a tool is first filled with the particle foam and foamed, then the cover layer in the liquid phase between the preform and the mold injection molded becomes. In this process sequence, however, the preform part of particle foam will collapse at the moment - due to a high temperature difference - in which the molten outer layer acts on the preform.

Kunststoff-Sandwichbauteile für den modernen Automobilbau haben eine große Bandbreite unterschiedlicher Anforderungen zu erfüllen, insbesondere gilt dies für den innovativen zukünftigen Leichtbau. Dabei geht es in der festen Außenhülle des Sandwichbauteils um hohe mechanische Festigkeiten bei gleichzeitiger guter Oberflächenqualität, während es im Schaumkern um zum Beispiel hohe spezifische Steifigkeiten, gutes Energieabsorptionsvermögen, Wärmespeichermöglichkeiten usw. geht.Plastic sandwich components for modern automotive engineering have to meet a wide range of different requirements, in particular for future innovative lightweight construction. It is in the fixed outer shell of the sandwich component to high mechanical strength while good surface quality, while it is in the foam core, for example, high specific stiffness, good energy absorption capacity, heat storage options, etc.

Die geschäumten Monomaterialien bieten solche Möglichkeiten durch eine Erweiterung ihrer Eigenschaften mittels Kombination aus metallischen, keramischen und polymeren Schäumen, den sogenannten Hybridschäumen. Zum Beispiel vereint ein aus EPP und APM (geschäumte Aluminiumpartikel) gefertigter Hybridschaum eine elastische flexible Verformbarkeit und eine plastische Energieabsorption. Ein Hybrid aus EPP und Keramikschaum kann zu thermischer Isolierung bei gleichzeitiger Wärmespeicherung führen.The foamed monomaterials offer such possibilities by extending their properties by means of a combination of metallic, ceramic and polymeric foams, the so-called hybrid foams. For example, a hybrid foam made of EPP and APM (foamed aluminum particles) combines elastic flexible ductility and plastic energy absorption. A hybrid of EPP and ceramic foam can result in thermal insulation while retaining heat.

Um all diese Forderungen zu erfüllen, wird die Aufgabe erfindungsgemäß mit folgendem Verfahren gelöst: Ein vorbehandeltes Halbzeug, welches zum Beispiel ein für das RTM-Verfahren vorkonsolidierter Prepreg sein kann oder ein für das Spritzgießverfahren vorbereitetes Organoblech, werden in das geöffnete Werkzeug der Anlage eingelegt und fixiert. Das Werkzeug wird geschlossen und je nach Verfahren wird das Harz injiziert (RTM) oder die Schmelze in die Kavität eingespritzt (Spritzgießen). Der im Anschluss über eine Werkzeugbewegung zu schaffende Formraum wird mit Partikelschaum oder auch hybridem Partikelschaum gefüllt und unter Temperatur und Druck versintert. Nach einer Abkühl- und Stabilisierungsphase kann das fertige Bauteil entnommen werden.To meet all these requirements, the object is achieved by the following method: A pre-treated semifinished product, which may for example be preconsolidated for the RTM process prepreg or prepared for the injection molding process Organoblech be inserted into the open tool of the system and fixed. The tool is closed and, depending on the process, the resin is injected (RTM) or the melt is injected into the cavity (injection molding). The mold space to be created subsequently via a tool movement is filled with particle foam or also hybrid particle foam and sintered under temperature and pressure. After a cooling and stabilization phase, the finished component can be removed.

ZITATE ENTHALTEN IN DER BESCHREIBUNG QUOTES INCLUDE IN THE DESCRIPTION

Diese Liste der vom Anmelder aufgeführten Dokumente wurde automatisiert erzeugt und ist ausschließlich zur besseren Information des Lesers aufgenommen. Die Liste ist nicht Bestandteil der deutschen Patent- bzw. Gebrauchsmusteranmeldung. Das DPMA übernimmt keinerlei Haftung für etwaige Fehler oder Auslassungen.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.

Zitierte PatentliteraturCited patent literature

  • DE 10024814 A1 [0002] DE 10024814 A1 [0002]
  • EP 1299219 [0003] EP 1299219 [0003]

Claims (4)

Verfahren zur Herstellung von Sandwichbauteilen aus hybridem Partikelschaum und wenigstens einer Deckschicht aus einem faserverstärkten Kunststoff in einem Formwerkzeug, mit folgenden Verfahrensschritten: a) Einlegen eines vorkonsolidierten Halbzeugs in die Form und Schließen der Form b) Einspritzen des schmelzflüssigen Kunststoffs in die Werkzeugkavität c) Nachdruckphase mit Teilabkühlung des Deckschicht-Vorformlings d) Befüllen des über mindestens eine Werkzeugbewegung zu schaffenden Formraums zwischen dem Deckschicht-Vorformling und mindestens einer Oberfläche der Kavität des Formwerkzeugs mit Partikelschaumkugeln e) Versintern der Partikelschaumkugeln unter Druck und Temperatur f) Abkühl- und Stabilisierungsphase des Partikelschaums g) EntnahmeMethod for producing sandwich components from hybrid particle foam and at least one cover layer made of a fiber-reinforced plastic in a molding tool, comprising the following method steps: a) placing a preconsolidated semi-finished product in the mold and closing the mold b) injecting the molten plastic into the mold cavity c) holding pressure phase with partial cooling of the top layer preform d) filling the mold space to be created by at least one tool movement between the cover layer preform and at least one surface of the cavity of the mold with particle foam balls e) sintering of the particle foam balls under pressure and temperature f) cooling and stabilizing phase of the particle foam g) removal Verfahren zur Herstellung von Sandwich-Bauteilen mit einem Kern aus hybridem Partikelschaum gemäß Anspruch 1a) bis 1f) und den anschließenden Verfahrensschritten: h) Einlegen eines weiteren vorkonsolidierten Halbzeugs und Schließen der Form i) Urformen einer weiteren Deckschicht j) Umsetzen des aus erster Deckschicht und Partikelschaum bestehenden Vorformlings mittels Werkzeugbewegung oder Handling zur geöffneten Kavität der weiteren Deckschicht k) Verschweißen der weiteren Deckschicht mit dem Vorformling l) EntnahmeProcess for the production of sandwich components with a core of hybrid particle foam according to claim 1a) to 1f) and the subsequent process steps: h) Inserting another preconsolidated semi-finished product and closing the mold i) prototyping another cover layer j) converting the preform consisting of the first cover layer and particle foam by means of tool movement or handling to the open cavity of the further cover layer k) welding the further outer layer to the preform l) removal Verfahren gemäß Anspruch 1 und 2 mit mindestens einer Deckschicht nach dem RTM-Verfahren.A method according to claim 1 and 2 with at least one cover layer according to the RTM method. Verfahren gemäß Anspruch 1 und 2 mit mindestens einer Deckschicht nach dem Spritzgieß-Verfahren.A method according to claim 1 and 2 with at least one cover layer by the injection molding method.
DE201210015715 2012-08-08 2012-08-08 Method for manufacturing of sandwich panels of hybrid particle foam and cover layer, involves inserting pre-consolidated preform into mold, and injecting molten plastic into tool cavity, where particle foam spheres are filled in mold space Withdrawn DE102012015715A1 (en)

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Application Number Priority Date Filing Date Title
DE201210015715 DE102012015715A1 (en) 2012-08-08 2012-08-08 Method for manufacturing of sandwich panels of hybrid particle foam and cover layer, involves inserting pre-consolidated preform into mold, and injecting molten plastic into tool cavity, where particle foam spheres are filled in mold space

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DE201210015715 DE102012015715A1 (en) 2012-08-08 2012-08-08 Method for manufacturing of sandwich panels of hybrid particle foam and cover layer, involves inserting pre-consolidated preform into mold, and injecting molten plastic into tool cavity, where particle foam spheres are filled in mold space

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3730272A1 (en) * 2019-04-12 2020-10-28 PARAT Beteiligungs GmbH Method for producing a flat component
DE102019127756A1 (en) * 2019-10-15 2021-04-15 Kaneka Belgium Nv Process for producing a foamed plastic molding with a film layer coating

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10024814A1 (en) 2000-05-19 2001-11-22 Bayerische Motoren Werke Ag Manufacture of sandwich component (2) employs non-impregnated fibrous mat which is back-foamed in the mold, extracted and impregnated by injection molding
EP1299219A1 (en) 2000-07-12 2003-04-09 Fraunhofer-Gesellschaft Zur Förderung Der Angewandten Forschung E.V. Method for producing moulded parts made of particle foam and comprising a covering layer

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10024814A1 (en) 2000-05-19 2001-11-22 Bayerische Motoren Werke Ag Manufacture of sandwich component (2) employs non-impregnated fibrous mat which is back-foamed in the mold, extracted and impregnated by injection molding
EP1299219A1 (en) 2000-07-12 2003-04-09 Fraunhofer-Gesellschaft Zur Förderung Der Angewandten Forschung E.V. Method for producing moulded parts made of particle foam and comprising a covering layer

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3730272A1 (en) * 2019-04-12 2020-10-28 PARAT Beteiligungs GmbH Method for producing a flat component
DE102019127756A1 (en) * 2019-10-15 2021-04-15 Kaneka Belgium Nv Process for producing a foamed plastic molding with a film layer coating

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R086 Non-binding declaration of licensing interest
R081 Change of applicant/patentee

Owner name: WOBBE, HANS, DR.-ING., DE

Free format text: FORMER OWNER: WOBBE, HANS, DR. ING., 82538 GERETSRIED, DE

Effective date: 20140320

R119 Application deemed withdrawn, or ip right lapsed, due to non-payment of renewal fee
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Effective date: 20150303