DE102020106927A1 - Method for producing a wall section for a transport and / or storage container - Google Patents

Abstract

The invention relates, inter alia, to a method for producing a wall section (10) for a transport and storage container in a sandwich lightweight construction.

Description

The invention relates to a method for producing a wall section for a transport and / or storage container in a sandwich lightweight construction.

Such methods have been developed by the applicant for decades and are being carried out on a large scale.

Reference is made to the applicant's German patent application by way of example only DE 10 2007 002 387 A1 , which already specifies a method for producing a transport and / or storage container in a sandwich lightweight construction. The content of this patent application is hereby included in the content of the present patent application to avoid repetition.

The method for the production of such a transport and / or storage container - which is also referred to as a container in the context of the present patent application for the sake of simplicity - provide that from different materials, such as plastic sheets, laminated cardboard, or metallic sheets, wall sections are manufactured individually, these wall sections are then provided by means of edge connector elements and connected to one another in order then to provide shell-shaped elements, in particular half-shells, for such a suitcase or a carrying case.

The shell border can, for. B. be filled by means of rolled profile elements to give the shell dimensional stability.

To provide storage compartments and storage compartments in the shells, separate partitions are used, which support the objects to be transported, eg. B. of tools, serve.

The arrangement of such storage compartments offers the user the possibility of an orderly, sorted accommodation of the tools or other objects to be transported.

Proceeding from this, the invention is based on the object of specifying a method with which a wall section for a transport and / or storage container can be manufactured which meets the requirements for low weight and high rigidity and can be manufactured inexpensively.

The invention solves this problem with the features of claim 1.

The principle of the invention consists first of all in using an expandable particle foam as the material for producing the wall section instead of the materials previously used.

Suitable expandable particle foams are, for example, particle foams made of EPS, EPE and EPP. These are particle foams which, when fully or fully foamed and cured, can have densities in the range from typically 15 kg / m ³ to 80 kg / m ³ .

According to a first variant of the invention, granular, that is to say loose, non-interconnected particles of a foamable particle foam are pre-foamed or end-foamed to form foamed particles. These expanded particles can be end-expanded or pre-expanded. In this context, final foaming means that no further foaming processes can be carried out while enlarging the particles. Pre-foamed means that the particles have already passed through a large part of the maximum possible increase in volume, but residual foaming can still be carried out.

The foamed particles are still in the form of granules, i.e. H. that is, loose, not interconnected particles. It is a pourable or pourable mass.

According to a first variant of the invention, the foamed particles are introduced directly into a lower tool and there are baked together under the action of temperature. A curable particle foam mass is generated. This is then left to harden.

According to an alternative of the invention, a film-like substrate is first provided before the foamed particles are introduced into the lower tool. It can, for example, be a deep-drawable film, e.g. B. act from ABS or PMMA. This can have a wall thickness between 0.01 mm and 13 mm, for example. The film can, for example, be deep-drawn in a first tool. The substrate used can, however, also be provided by a thin skin, a thin film or another sheet-like material. The substrate does not have to be deep-drawn.

According to the variant of the invention, the substrate is arranged in a lower tool. The The lower tool has in particular a receiving space for particles, which will be explained in more detail later.

The method according to the invention now provides that granular starting material is provided in the form of loose particles of a foamable particle foam. Materials known as expandable particle foams come into question. In particular, this is understood to mean expandable particle foams made of EPS, EPE, or EPP, or also expandable PEEK. A further definition is given below.

The granular starting material can be provided in the form of small spheres or pearls used, or in the form of granular particles of other regular or even irregular shape and geometry. In particular, the starting material is pourable.

The particles are loosely present in the granular starting material; H. especially not yet firmly connected to each other.

According to a variant of the invention, the step of partial or complete foaming of the particles now takes place. Partial foaming means that the particles are not yet fully foamed. For example, according to the invention it can be provided that, based on a foaming or expansion process from 0 to 100% starting from the volume of the particles of the starting material to the volume of the particles in the final foamed state, partial foaming between 30 and 95% takes place. The term partial foaming comprises in particular embodiments of the invention in which at least the step of additional foaming of the particles can still be carried out, leading to a final foamed state of the particles.

The foaming step takes place in particular - but not necessarily - at a location that is remote from the lower tool. The particles can also advantageously be foamed in an oven, in particular in an infrared oven.

According to a further step of the method according to the invention, it can be provided that the partially or completely foamed particles are brought into the lower tool. The foamed particles can be transported, for example, immediately after the step of foaming the particles has been carried out. However, it can also be carried out significantly later in time after the step of foaming the particles has been carried out.

Bringing and / or arranging or positioning the foamed particles in the lower tool can be done mechanically, automatically or manually.

According to the invention, the tool is now closed in particular. For this purpose, for example, an upper tool can move against the lower tool and close a receiving space or accommodation space for the foamed particles - as well as for the substrate located in the lower tool.

According to the invention, the tool is also heated. The invention also encompasses when the tool is kept constantly at a constant temperature or at a temperature within a predetermined temperature range.

According to the variant of the invention described above, the particles, which have already been partially foamed beforehand, are caked, and possibly also at the same time also final foaming, to form a foamed particle foam. The particles now expand - if not already done - to their maximum extent or to their maximum volume, and bake or sinter with one another, so to speak. The particle foam mass bonds with the substrate at the same time. The activation of any planned residual foaming process takes place via the mold temperature. The invention also includes, in addition or as an alternative, using other activating agents to activate and carry out the residual foaming process of the particles, that is to say for the foaming process of the particles that have already been partially foamed up to a final foamed state of the particles.

At this point it should be noted again that such a substrate does not have to be present in a variant of the invention.

It should also be noted at this point that in a variant of the invention the foamed particles are already foamed or completely foamed when they are introduced into the lower tool, and are only baked or sintered together in the lower tool.

According to the invention, the particle foam mass is then allowed to harden. As a result of this hardening process, the particle foam mass forms a permanent and permanent bond with the substrate, if any.

After the particle foam mass has hardened, the tool can be opened and the thus formed molding can be removed. The molding formed in this way represents the wall sections to be produced according to the invention for a transport and / or storage container.

The wall section can - depending on the configuration of the invention - now be assembled with other wall sections, for example to form a shell-shaped body. Two such shell-like bodies can already form the, for example, cuboid transport and / or storage container.

The invention also encompasses when a wall section produced using the method described above itself has a shell shape. In the simplest case, a shell or half-shell of such a transport and / or storage container can be manufactured in one piece - in one go.

The invention also includes when the wall section has a first area which is arranged along a plane, and at least one second area which extends transversely to this plane, in particular at right angles to the plane. In this way, wall sections can be provided which directly have storage compartment arrangements or accommodation spaces. In this way, a division of a half-shell of a transport and / or storage container can be achieved in a simple manner.

The partition walls that delimit the storage compartment or the accommodation space are thus integrally connected to the wall section in a materially bonded manner.

To this extent, the production of a corresponding container is extremely simple.

• Als expandierbare Partikelschäume im Sinne der vorliegenden Patentanmeldung werden beispielsweise folgende Materialien angesehen:
  • Unter der Abkürzung EPS wird expandierbares Polystyrol bezeichnet. Dieses ist beispielsweise unter der Markenbezeichnung Styropor bekannt, und kann z. B. von der Firma Metz EPS-Hartschaumzuschnitte in 74376 Gemmrigheim bezogen werden.

Definition of expandable particle foam:

• The following materials, for example, are regarded as expandable particle foams within the meaning of the present patent application:
  • Expandable polystyrene is the abbreviation EPS. This is known, for example, under the brand name Styrofoam, and can, for. B. from the company Metz EPS hard foam blanks in 74376 Gemmrigheim.

Expandable polyethylenes (EPE) are also regarded as particle foams in the context of the present patent application. Finally, expandable polypropylenes (EPP) are also considered to be well suited for the purposes according to the invention.

In particular, the term particle foam in the sense of the present patent application includes thermoplastic particle foams. These can have granules, in particular also microgranules, for example with diameters of the particles in the order of magnitude of between 0.1 mm and 5 mm, more preferably particles with a diameter of approximately 1 mm.

Propellants are preferably arranged in the granular starting material particles of the particle foam. These can be activated thermally and / or by chemicals, for example also by the action of water vapor, in order to trigger the foaming process.

The process of baking pre-expanded particles together is also referred to as sintering in the context of the present patent application.

A suitable blowing agent for polystyrene particle foam particles is, for example, pentane, which is polymerized into the granular particles. As soon as the particles are exposed to temperatures of over 100 ° C, the propellant can evaporate, thereby expanding the thermoplastic base material into polystyrene foam particles.

According to the invention, the optionally provided second foaming stage can take place in the lower tool, the tool temperature being selected so that the blowing agent can finally evaporate and the particles can finally foam.

In addition to EPS (extrudable polystyrene), XPS can also be considered for the invention.

A possible source of supply for expandable polypropylene EPP or XPS is, for example, the company Schaumaplast GmbH & Co. KG in 68799 Reilingen.

Particle foams for use with the invention can also be provided by expandable copolymers. Such materials can be obtained, for example, under the trade name Grupor from Kunststoffwerk Katzbach GmbH & Co. KG in 93413 Cham.

Expandable PEEK (polyetheretherketone) can also be used as the starting material for the particle foam that can be used in the context of the invention. This is available for example under the trade names Gatone or Victrex.

The method according to the invention is used to produce a wall section with a high-quality surface. The surface of the finished wall section can, for example particularly resilient, e.g. B. be particularly impact-resistant.

The invention relates to a method for producing a wall section. This can be designed flat. The term planar means that the wall section extends along a surface in the x and y directions considerably longer than in a z direction perpendicular thereto. The wall section can be flat or curved in space, also curved several times, and any desired spatial shape, eg. B. also assume a shell shape, in particular with partitions arranged thereon.

According to an advantageous embodiment of the invention, the particle foam mass is baked against a substrate, the substrate being covered by a film, e.g. B. is provided by a deep-drawn film. This enables recourse to conventional components that have already been extensively tested on other components and, in particular, enable the provision of a high-quality surface for the wall section.

According to a further advantageous embodiment of the invention, step k) is carried out: application of a cover layer to the side of the particle foam mass facing away from the substrate. Such a cover layer can be, for example, an interior decorative layer, for example wall paneling, in particular a plastic layer.

The interior decorative layer can, for example, provide the inside of the shell of the transport and / or storage container. The interior decorative layer can also be a lacquer layer, for example.

According to a further advantageous embodiment of the invention, the method according to the invention comprises the following step:

Processing of the molding.

Various processing methods come into consideration as processing steps. This includes, for example, if necessary, separating or severing parts or areas of the molding, possibly also separating or separating sections of the substrate. This includes B. also a step of cleaning and / or a step of surface treatment, in particular on the outside of the cured particle foam mass, and / or - if a substrate is present - in particular on the outside of the substrate, for example roughening or polishing or smoothing the surface , possibly also the application of an additional layer or film, for example an additional functional layer.

The invention also includes when the side of the cured particle foam mass facing away from the substrate is processed, for example connected to or applied to an additional skin or an additional material or a film, e.g. B. sprayed, glued, painted, riveted, screwed or glued to another element.

According to a further advantageous embodiment of the invention, the film has a wall thickness between 0.01 mm and 2 mm. This embodiment of the invention also allows recourse to conventional foils, which could be tested on numerous composite materials and whose deep-drawing properties and surface properties are sufficiently known and researched.

According to a further advantageous embodiment of the invention, the cured particle foam mass has a wall thickness between 0.3 cm and 5 cm. The wall thickness of the cured particle foam mass is calculated and designed as a function of the required strengths of the manufactured wall section. Despite the relatively high wall thicknesses, the finished wall section can only have a very low weight.

According to a further advantageous embodiment of the invention, the granular starting material comprises expandable EPS, expandable EPP or expandable PEEK. It is all here to materials that are foamable, i. H. are expandable, and which, according to the invention, are suitable for being completely foamed or initially only partially foamed or expanded in order to subsequently go through a step of final foaming or final expansion in a tool.

• m) Positionieren von Einlegerelementen, insbesondere Verstärkungselementen, insbesondere nach Art von Zugankern, beispielsweise nach Art von Tapes oder insbesondere von Schraubaufnahmen oder von Scharnieren oder Teilen von Scharnieren, in dem Unterwerkzeug, wobei nach dem Verbringen der teilweise aufgeschäumten Partikel (31a, 31b, 31c) in das Unterwerkzeug (23) diese die Verstärkungselemente Einlegerelemente umhüllen.

According to a further advantageous embodiment of the invention, the method comprises step m), which is carried out before step iii):

• m) Positioning of insert elements, in particular reinforcing elements, in particular in the manner of tie rods, for example in the manner of tapes or in particular screw receptacles or hinges or parts of hinges, in the lower tool, whereby after the introduction of the partially foamed particles ( 31a , 31b , 31c ) into the lower tool ( 23 ) these envelop the reinforcing elements insert elements.

According to this advantageous embodiment of the invention, the end-foamed, expanded particle foam mass z. B. reinforced or stiffened by reinforcing elements. These are designed in particular so that they can transmit tensile forces in a direction transverse to the flat extension of the wall section. This can increase the rigidity of the wall section. The invention also includes when the reinforcing elements extend along the extension direction of the flat wall section. For example, flat structures such as mats, non-woven fabrics, knitted fabrics, etc. made of reinforcing fibers, for example made of glass fibers, carbon fibers, aramid fibers, basalt fibers or other suitable reinforcing fibers, can be inserted into the lower tool before the filling into the accommodation space with partially foamed particles.

According to this embodiment of the invention, other insert elements can also be provided, for example screw receptacles and / or hinges and / or parts of hinges. These insert elements can also be enveloped by the hardenable particle foam mass and form a firm connection with the hardened particle foam mass.

According to a further aspect, the invention relates to a transport and / or storage container according to claim 15.

The invention is based on the object of specifying a transport and / or storage container which, while being only light in weight, has high strength and load-bearing capacity and can be manufactured inexpensively.

The invention solves this problem with the features of claim 15.

To avoid repetition, reference is made in an analogous manner to the previous statements on claims 1 to 14 with regard to the explanation and explanation of the features of claim 15 and to explain the invention according to claim 15.

• 1 in einer teilgeschnittenen schematischen Ansicht ein Ausführungsbeispiel eines Ofens, in welchen granulares Ausgangsmaterial in Form von Partikeln eines Partikelschaumes eingefüllt wird, wobei das granulare Ausgangsmaterial ungeschäumt ist,
• 2 den Ofen der 1 mit einer zusätzlich dargestellten Infrarot-Strahlungsheizung, wobei die zuvor eingefüllten Partikel in einen aufgeschäumten Zustand überführt worden sind,
• 3 ein erstes Werkzeug mit Unterwerkzeug und Oberwerkzeug und einer als Substrat ausgebildeten Folie in bahnförmigem, flachliegendem Zustand,
• 4 das geschlossene Werkzeug der 3 mit tiefgezogener Folie,
• 5 ein weiteres Werkzeug, in dem die tiefgezogene Folie der 4 positioniert ist, wobei in das Unterwerkzeug die aufgeschäumten Partikel des Partikelschaums gemäß 2 eingefüllt werden,
• 6 das Werkzeug der 5 mit zusätzlich dargestelltem Oberwerkzeug kurz vor dem vollständigen Schließen des Werkzeugs,
• 7 das Werkzeug der 6 in vollständig geschlossenem Zustand, wobei zusätzlich eine Heizeinrichtung für das Werkzeug dargestellt ist,
• 8 das Werkzeug der 7 in geöffnetem Zustand bei aufgeschäumter, miteinander verbackener, ausgehärteter Partikelschaummasse,
• 9 den aus dem Werkzeug der 8 entnommenen Formling unter Andeutung von Trennlinien, entlang derer Überstandsbereiche des Substrats getrennt werden,
• 10 ein weiteres Ausführungsbeispiel eines Formlings bzw. eines nach dem erfindungsgemäßen Verfahren gebildeten erfindungsgemäßen Wandungsabschnittes mit einer zusätzlichen Schicht auf der dem Substrat abgewandten Seite der ausgehärteten Partikelschaummasse,
• 11 ein weiteres Ausführungsbeispiel eines erfindungsgemäßen Wandungsabschnittes in einer Darstellung gemäß 10, wobei lediglich zu Illustrationszwecken die Porenstruktur des ausgehärteten Partikelschaumes in einer gegenüber 10 geänderten Weise dargestellt ist,
• 12 in einer perspektivischen schematischen Ansicht ein Ausführungsbeispiel eines erfindungsgemäßen Transport- und/oder Aufbewahrungsbehältnisses nach Art eines Koffers,
• 13a das Behältnis der 12 im geöffneten Zustand unter Erkennbarkeit der beiden Halbschalen,
• 13b das Behältnis der 13a mit zusätzlich dargestellten Schnittebenen,
• 14 in einer Darstellung vergleichbar 5 ein Werkzeug mit Oberwerkzeug und Unterwerkzeug im geöffneten Zustand, wobei aufgeschäumte granulare Partikel in den Innenraum des Werkzeugs eingebracht werden,
• 15 das Werkzeug der 14 im geschlossenen Zustand im Moment des Verbackens der Partikelschaummasse,
• 16 den aus dem Werkzeug der 15 entnommenen schalenförmigen Formling, der einen Wandungsabschnitt des Transportbehältnisses bereitstellt, in Einzeldarstellung in einer Schnittdarstellung etwa entlang Schnittebene XVI-XVI der 13b,
• 17 eine Variante eines Werkzeugs in einer Darstellung gemäß 14, wobei das Oberwerkzeug mehrere sich im wesentlichen vertikal erstreckende Ausnehmungen Schlitze aufweist,
• 18 in einer Darstellung gemäß 16 den aus dem Werkzeug der 17 entnommenen Formling unter Bereitstellung eines erfindungsgemäßen Wandungsabschnittes, der mehrere Trennwände unter Ausbildung von Staufächern bereitstellt, wobei die Darstellung der 18 etwa einer Schnittansicht entlang der Schnittebene XVIII - XVIII in 13b entspricht, und
• 19 ein weiteres Ausführungsbeispiel eines erfindungsgemäßen Wandungsabschnittes in einer Darstellung gemäß 18 mit zusätzlich angebrachter Folie.

Further advantages of the invention emerge from the subclaims that are not cited, and from the following description of the exemplary embodiments shown in the drawings. Show in it:

• 1 in a partially sectioned schematic view an embodiment of a furnace, in which granular starting material in the form of particles of a particle foam is filled, wherein the granular starting material is unfoamed,
• 2 the furnace of the 1 with an additionally shown infrared radiation heater, whereby the previously filled particles have been converted into a foamed state,
• 3 a first tool with a lower tool and an upper tool and a film designed as a substrate in a sheet-like, flat state,
• 4th the closed tool of the 3 with deep-drawn foil,
• 5 Another tool in which the deep-drawn film of the 4th is positioned, the foamed particles of the particle foam according to FIG 2 be filled,
• 6th the tool of 5 with the upper tool also shown shortly before the tool closes completely,
• 7th the tool of 6th in a completely closed state, with a heating device for the tool also shown,
• 8th the tool of 7th in the open state with foamed, cured, hardened particle foam mass,
• 9 from the tool of the 8th Removed molding, indicating parting lines along which protruding areas of the substrate are separated,
• 10 a further embodiment of a molding or a wall section according to the invention formed by the method according to the invention with an additional layer on the side of the cured particle foam mass facing away from the substrate,
• 11 a further embodiment of a wall section according to the invention in a representation according to FIG 10 , with the pore structure of the cured particle foam in one opposite position for illustration purposes only 10 is shown in a changed manner,
• 12 in a perspective schematic view an embodiment of a transport and / or storage container according to the invention in the manner of a suitcase,
• 13a the container of the 12 in the open state with the two half-shells recognizable,
• 13b the container of the 13a with additionally shown cutting planes,
• 14th comparable in a representation 5 a tool with upper tool and lower tool in the open state, wherein foamed granular particles are introduced into the interior of the tool,
• 15th the tool of 14th in the closed state at the moment of the caking of the particle foam mass,
• 16 from the tool of the 15th removed shell-shaped molding, which provides a wall section of the transport container, in an individual illustration in a sectional illustration approximately along section plane XVI-XVI of FIG 13b ,
• 17th a variant of a tool in a representation according to 14th , wherein the upper tool has a plurality of substantially vertically extending recesses slots,
• 18th in a representation according to 16 from the tool of the 17th removed molding with provision of a wall section according to the invention, which provides a plurality of partition walls with the formation of storage compartments, the illustration of the 18th about a sectional view along the sectional plane XVIII - XVIII in 13b corresponds to, and
• 19th a further embodiment of a wall section according to the invention in a representation according to FIG 18th with additionally attached foil.

Exemplary embodiments of the invention are described in the following description of the figures, also with reference to the drawings. For the sake of clarity, the same or comparable parts or elements or areas are denoted by the same reference numerals, sometimes with the addition of small letters, even if different exemplary embodiments are concerned.

Features that are described, illustrated or disclosed only in relation to one exemplary embodiment can also be provided in any other exemplary embodiment of the invention within the scope of the invention. Such modified exemplary embodiments - even if they are not shown in the drawings - are also covered by the invention.

All of the features disclosed are essential to the invention. In the disclosure of the application, the disclosure content of the associated priority documents (copy of the prior application) as well as the cited documents and the described devices of the prior art are hereby fully included, also for the purpose of integrating individual or several features of the objects disclosed therein or to be included in several claims of the present application. Such modified exemplary embodiments are also encompassed by the invention - even if they are not shown in the drawings.

Embodiments of wall sections that have been manufactured according to the method according to the invention are shown in FIGS 8th , 9 , 10 , 11 as well as 16, 18 and 19 denoted by 10 in their entirety.

• Ausweislich 1 ist ein Behältnis 12 dargestellt, in welches ein Granulat 11 eines Partikelschaumes eingefüllt wird. Die einzelnen Granulatpartikel, die beispielhaft mit den Bezugszeichen 30a, 30b, 30c bezeichnet sind, sind ungeschäumt, und stellen das Ausgangsmaterial zur Fertigung eines Partikelschaumes dar. Auf die einzelnen Materialien, die gemäß dem erfindungsgemäßen Verfahren verwendet werden können, wird später noch detailliert eingegangen.

In the following, based on 1 the method for manufacturing such a wall section 10 to be introduced:

• Evidence 1 is a container 12 shown in which a granulate 11 a particle foam is filled. The individual granulate particles, for example with the reference numerals 30a , 30b , 30c are not foamed, and represent the starting material for the production of a particle foam. The individual materials that can be used in accordance with the method according to the invention will be discussed in detail later.

• Hierzu ist eine Heizung 14, insbesondere eine Infrarotheizung 14, vorgesehen, die unter Verwendung von Infrarotstrahlen 15 (angedeutet) in den Ofen 13 eine vorherbestimmte Strahlungsleistung einbringt, um eine bestimmte Temperatur oder einen bestimmten Temperaturbereich zu erreichen. Die Granulatpartikel 30a, 30b, 30c werden in dem Ofen 13 der Temperatureinwirkung für eine vorherbestimmte Zeit ausgesetzt und schäumen teilweise oder vollständig auf. Man erkennt, dass die einzelnen Partikel 30a, 30b, 30c der 1 erheblich an Volumen gewinnen und gemäß 2 zu teilweise oder vollständig aufgeschäumten Partikeln 31a, 31b, 31c mutieren.

Evidence 2 is the container 12 Part of an oven 13 in which the granulate particles 30a , 30b , 30c can be partially or fully foamed:

• There is a heater for this 14th , especially an infrared heater 14th , provided that using infrared rays 15th (indicated) in the oven 13 introduces a predetermined radiation power in order to reach a certain temperature or a certain temperature range. The granulate particles 30a , 30b , 30c be in the oven 13 exposed to the effects of temperature for a predetermined time and foam partially or completely. You can see that the individual particles 30a , 30b , 30c of the 1 gain significantly in volume and accordingly 2 to partially or completely foamed particles 31a , 31b , 31c mutate.

It should be noted that the figures are of course not to be understood to be true to scale, but that the process of foaming and the increase in volume are only intended to be shown by way of example.

The partially or fully foamed particles 31a , 31b , 31c are in the form of granules, ie they are still loose, in particular not connected to one another. During the partial foaming process according to 2 can be done through additional measures, such as shaking the container 12 , Stirring, using chemicals, or adding chemicals to the container 12 etc. can be achieved that the particles 31a , 31b , 31c do not connect with each other or do not predominantly connect with each other, but can still be transported as loose, pourable or at least pourable mass. This mass is evidenced 5 in a lower tool 23 of a tool 17b filled.

• Ausweislich 3 wird ein erstes Werkzeug 17 bereitgestellt, welches ein Oberwerkzeug 18 und ein Unterwerkzeug 19 umfasst. Die maßgeblichen Werkzeugteile können nach Art einer Matrize und nach Art einer Patrize ausgebildet sein. Man erkennt in 3 eine Folie 20 in flachliegendem, bahnförmigen Zustand, also einem Ausgangszustand. 3 zeigt das Werkzeug in geöffnetem Zustand.

First of all, using the 3 to 4th - According to a variant of the invention - the production of a substrate 21st explained:

• Evidence 3 becomes a first tool 17th provided, which an upper tool 18th and a lower tool 19th includes. The relevant tool parts can be designed in the manner of a die and in the manner of a male mold. One recognizes in 3 a slide 20th in a flat, sheet-like state, i.e. an initial state. 3 shows the tool in the open state.

As a result of closing the tool, the film 20th Deep-drawn from the flat state. Any spatial contour can be applied to the film by the deep-drawing process. The deep-drawing process can - which is not shown in the figures - be supported in a conventional manner by temperature. For the deep-drawing process, there is an alternative to the stamping / swaging process of the tool 17th of the 3 blow molding processes or other forming processes in which the film is heated and brought into its final shape by suction can also be considered.

After opening the tool 17th from the state of 4th can the deep-drawn film 21st can be removed and fed to another tool. Such a second tool 17b is in the 5 to 8th shown.

The invention also encompasses when the film 21st after the deep drawing process in the lower tool 19th remains, and only the upper tool is replaced. In the following it is assumed that starting from 5 who have favourited deep-drawn foil 21st into another, second lower tool 23 another tool 17b was spent.

Evidence 5 is in the lower tool 23 in an accommodation room 22nd , the one to absorb the partially or completely foamed particles 31a , 31b , 31c , serves, and that of the back 35 the deep-drawn film 21st is facing, the pourable or pourable mass of partially or completely foamed particles 31a , 31b , 31c spent. A filling of the second lower tool 23 or the designated accommodation space 22nd , can be done manually or by machine or machine-assisted until a given volume or a given mass of partially or completely foamed particles 31a , 31b , 31c in the accommodation room 22nd is positioned and in particular also distributed.

In this case, a discharge or discharge device, not shown in the figures, can be provided which, in the manner of a feed head, moves the particles along the accommodation space 22nd equally distributed.

Then the tool 17b closed. An upper tool is used for this 24 starting from a state according to 6th in which the tool 17b is still partially open, move into a closed state. The accommodation room 22nd is now closed on all sides.

7th indicates a heater 25th who have favourited the tool 17b , preferably both lower tool 23 as well as upper tool 24 , tempered. The mold temperature is selected according to the materials used for the particle foam.

• Hier ist anstelle der Rahmenstruktur der 8 eine unregelmäßige, polygonartige Struktur in der schematischen Schnittdarstellung gezeigt.

As a result of the effect of temperature, the partially foamed particles become 31a , 31b , 31c completely foamed. One recognizes - only indicated by way of example in 8th - a honeycomb structure. This is also to be understood only schematically: in fact, the structure of the completely foamed particle foam will be irregular. Another comparable structure shows 11 :

• Instead of the frame structure, here is the 8th an irregular, polygonal structure shown in the schematic sectional view.

8th makes it clear that the partially foamed particles 31a , 31b , 31c according to 7th to completely foamed particles 32a , 32b , 32c mutate, and thereby baked together, whereby between individual foamed particles 32a , 32b , 32c no more free spaces remain. 7th indicates such free spaces, denoted by, for example 36 , however still on.

• Tatsächlich bildet die Vielzahl der vollständig aufgeschäumten Partikel 32a, 32b, 32c insgesamt eine vollständig aufgeschäumte Partikelschaummasse 33 oder einen vollständig aufgeschäumten Partikelschaum. Dieser kann ausweislich 8 auch innerhalb kurzer Zeit aushärten, so dass - wie 8 andeutet - das Werkzeug geöffnet, und das Oberwerkzeug 24 von dem Unterwerkzeug 23 abgehoben werden kann. Nun kann der so gebildete Formling 10 aus der Werkzeugform entnommen werden.

It should be noted that the term “completely foamed particles 32a , 32b , 32c "Is misleading:

• In fact, the plurality of fully foamed particles form 32a , 32b , 32c overall a completely foamed particle foam mass 33 or a fully expanded particle foam. This can be evidenced 8th also harden within a short time, so that - like 8th indicates - the tool open, and the upper tool 24 from the lower tool 23 can be withdrawn. Now the molding formed in this way can 10 can be removed from the mold.

As a result of the final foaming process - with the mold closed - the particle foam bonds permanently and firmly to the inside 35 the deep-drawn film 21st . This provides a lightweight, rigid and stable composite component that can be produced at low cost.

It should be noted at this point that only the variant of the invention has recently been described in which the foamed particles at the time of introduction into the lower tool 23 have not yet been completely foamed, and in this respect experience an increase in volume in the lower tool in the course of the baking process.

The invention also encompasses methods and wall sections produced therefrom, in which the foamed particles 31a , 31b , 31c at the time of introduction into the lower tool 23 although they are still present as granules, i.e. as loose, not interconnected, particles, these have already been foamed at the end. In the subsequent process of caking the particles 31a , 31b , 31c with each other within the lower tool 23 or with the mold closed 17b In this respect, there is no increase in the volume of these particles 31a , 31b , 31c but these only change their shape. The invention also includes when a volume reduction takes place in the course of the baking process.

The formed molding 10 provides a wall section produced by the method according to the invention. According to 9 can be shown there 34a , 34b the slide 21st along the dividing lines 29a , 29b be separated.

The embodiment of 10 shows the back 27 of the component 10 that with an extra layer 28 , e.g. B. made of plastic, can be provided.

Wall sections are also part of the invention 10 includes, where instead of a deep-drawn film 21st made of ABS or PMMA, a thin film made of polyethylene or polypropylene, or in particular so-called slush skins, as a substrate 21st can be used.

The page 26th the deep-drawn film 21st that of the cured particle foam mass 33 is turned away, can form a high quality surface. As for the provision of a deep-drawn film 21st conventional known and proven materials can be used, the corresponding surface properties of conventional materials can be used.

The invention also includes when the surface 26th of the substrate 21st is subjected to a separate processing in order to provide a high-quality surface. For example, processing steps such as polishing, painting, steaming, roughening, wetting, etc. can be considered.

In 8th are exemplary the wall thicknesses W1 the deep-drawn film 21st or the substrate and W2 , namely the wall thickness of the cured particle foam mass 33 indicated. The wall thickness W1 can be between 0.01 mm and 2 mm, and the wall thickness W2 between 1 cm and 30 cm.

The invention further comprises embodiments which provide that before the accommodation space is filled 22nd with partially foamed particles 31a , 31b , 31c Insert elements, in particular reinforcing elements in the accommodation space 22nd be accommodated.

The reinforcing elements not shown in the figures can, for. B. have reinforcing fibers. As a result of filling the accommodation space 22nd with partially foamed particles 31a , 31b , 31c the particles are evenly distributed and envelop the reinforcing elements on several sides, preferably on all sides. The finished wall section 10 comprises a cured particle foam mass that securely encloses the reinforcement elements. By positioning the reinforcement elements, tensile forces in particular can be transmitted and absorbed.

• Bei diesen Ausführungsformen der Erfindung werden aufgeschäumte Partikel 31a, 31b, 31c unmittelbar in das Unterwerkzeug 23 eingebracht, ohne dass in dieses zuvor ein Substrat 21 eingelegt ist.

Wall sections are also from the invention 10 and processes for their preparation which are carried out without one in the 3 to 11 shown slide 21st or get by with a substrate:

• In these embodiments of the invention, foamed particles are produced 31a , 31b , 31c directly into the lower tool 23 introduced without a substrate in this beforehand 21st is inserted.

The wall sections described above 10 are continuously designed as flat wall sections 10 shown in the schematic drawings. The invention includes in particular wall sections which are formed along a plane or essentially along a plane, or which are essentially planar, ie have an extension along an XY plane that is significantly larger than the extension in one of them vertical Z direction.

In the event that the wall section produced by the method according to the invention 10 is formed along a plane, can For example, the six side parts of an essentially cuboid transport and / or storage container from six such flat wall sections after a corresponding cut 37 be manufactured, for example in 12 is shown. 12 shows, in a schematic, perspective view, such a suitcase on its top wall 45 a handle 39 having. The case can be made up of two half-shells 40a and 40b exist in the area of a hinge arrangement ( 54a , 54b) around a pivot axis 42 are pivotally connected to each other.

According to a variant of the invention, for example, a side wall 43 from a wall section 10 according to one of the embodiments of 9 to 11 be ready. This wall section according to the side wall 43 can over edge pieces 44 with adjacent sections, e.g. B. with the ceiling wall 45 get connected. Suitable fastening methods can be used for this, such as screwing, gluing, welding, clamping, etc.

A side wall 43 and four perpendicular to the side wall 43 trained sections 45 , 46 , 47 and 48 can together make a half-shell 40 form.

It is also conceivable that z. B. the ceiling wall sections 49 and 45 of the two different half-shells 40a , 40b from a common wall section 10 which has been separated into two parts.

A transport and / or storage container 37 according to 12 In this variant of the invention, it consists of at least ten different wall sections 10 together.

A production that is even further simplified in comparison is now to be made using the exemplary embodiments of FIG 14th to 19th to be discribed.

14th shows a tool 17c with an upper tool 24 and lower tool 23 . With the tool closed according to 15th form lower tool 23 and upper tool 24 between them an accommodation room 22nd , which is formed substantially cup-shaped.

Evidence 14th is with the tool initially still open - similar to the example of FIG 5 described - a multitude of foamed granular particles 31a , 31b , 31c into the accommodation room 22nd introduced, the direction of introduction being denoted by 50. The introduction can take place manually, by machine, automatically, also with the aid of a dispensing device or with the aid of tools, which the foamed particles 31a , 31b , 31c distribute within the accommodation room.

After filling the interior 22nd of the tool 17c takes place in the step of baking the foamed particles 31a , 31b , 31c to a homogeneous curable particle foam mass 33 instead of. After allowing the particle foam to harden 33 can the tool 17c opened and the molding 10 can be removed.

As evidenced by the exemplary embodiment of 16 has the wall section thus formed 10 a shell shape. This shell shape can according to the sectional view XVI-XVI in 13 the shape of the half-shells of the transport and / or storage container shown there 37 correspond.

In this respect, the wall section 10 according to 16 the bottom section 43 of the transport container 37 according to 12 and the side walls 46 , 48 of the molding 10 the narrow side walls 46 , 48 the half-shell 40b of the transport container 37 according to 12 provide. From the floor section extending along a plane 43 of the wall section 10 stand side wall sections 46 and 48 at right angles or substantially at right angles. These serve to form the narrow side sections 46 and 48 of the transport container 37 according to 12 .

Of course, it is - without this requiring further special mention - provided in the exemplary embodiments of the invention that the longitudinal side wall sections are also provided 45 and 47 of the transport container 37 according to 12 in one piece with a material fit on the bottom wall 43 of the molding 10 can also be molded to form a shell shape.

The wall section 10 according to the 15th and 16 can in this respect form a completely closed shell shape that is only to one side, namely based on 16 , up, is open.

Based on the embodiment of 17th to 19th becomes another tool 17d with a modified upper tool 24 and a lower tool 23 presented. Here are in the upper tool 24 Recesses 51a , 51b provided, which when the tool is closed 17d the accommodation room 22nd expand. This tool 17d is used to produce a molding 10 , so a wall section 10 , according to 18th .

The wall section 10 according to 18th corresponds to the wall section 10 according to 16 , with additional two partitions 52a , 52b are formed. In the present case, the partition walls are created during manufacture in that the recesses 51a , 51b with foamed particles 31a , 31b , 31c are filled, and there also to a cured particle foam mass 33 baked.

The shell element with the dividing walls on the inside 52a , 52b offers in this way the provision of storage compartments 53a , 53b , 53c as they are in the lower shell 40b of the transport container according to 13a are shown.

According to this variant of the invention, a half-shell can be used 40a a transport and / or storage container 37 can be produced in one cast, ie in one piece in a single process step. In particular, the partitions 52a , 52b in one piece with a material fit on the bottom wall 43 of the wall section 10 according to 18th set.

The embodiment of 19th finally corresponds to the embodiment of FIG 18th , taking an additional slide 21st is appropriate. This film corresponds to that in the exemplary embodiments of FIG 3 to 11 described slide 21st .

The foil 21st can in this respect again - before the molding is baked 10 - are placed in the lower tool and baked in one go with the hardening particle foam mass.

The invention also encompasses when the layer 21st subsequently, that is, after the molding has been produced according to 18th , is attached to this, for example by gluing, welding, or by applying a layer of lacquer. Other types of lamination are also encompassed by the invention.

In the 13 indicated hinge arrangements 54a , 54b can partially or completely as insert elements in the lower tool 23 be positioned before the foamed particles 31a , 31b , 31c be introduced and baked there. In the course of the caking process and the subsequent curing of the particle foam 33 are the insert elements 54a , 54b completely encased and enclosed, and firmly embedded in the particle foam, which forms a kind of matrix for these elements.

Insert elements can be partially or completely enclosed.

Overall, the proposed method enables the production of a lightweight transport and / or storage container 37 possible at low cost, which meets the requirements for durability and stability.

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was 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.

Patent literature cited

• DE 102007002387 A1 [0003]

Claims (17)

Method for producing a wall section (10) for a transport and storage container in sandwich lightweight construction, comprising the following steps: i. Provision of granular starting material in the form of loose particles (30a, 30b, 30c) of a foamable particle foam, such as EPS, EPE or PEEK, ii. partial or complete foaming of the particles (30a, 30b, 30c), in particular in an infrared oven, iii. Bringing the foamed particles (31a, 31b, 31c) into a lower tool (23) of a tool (17b), and arranging the foamed particles (31a, 31b, 31c) in an accommodation space (22) in the lower tool (23), iv. Closing the tool (17b), v. Heating the tool (17b), vi. Baking the foamed particles (31a, 31b, 31c) to form a homogeneous, curable particle foam (33), vii. Allowing the particle foam (33) to harden, viii. Opening the tool (17b) and removing the molding (10) of the wall section thus formed, ix. Connecting the wall section with further wall sections to provide a transport and storage container (37). Procedure according to Claim 1 , characterized in that the wall section provides a complete or an almost complete side surface of an in particular cuboid or essentially cuboid transport and / or storage container (37). Procedure according to Claim 1 , characterized in that the wall section has a shell shape. Procedure according to Claim 3 , characterized in that the wall section provides a shell part of the transport and / or storage container, in particular a half-shell of a transport and / or storage container. Method according to one of the preceding claims, characterized in that the wall section is oriented along a plane, or comprises an area or section which is oriented along a plane. Method according to one of the preceding claims, characterized in that at least one further area is connected to the wall section in one piece with a material fit and extends along a plane which is perpendicular to the plane of the wall section. Method according to one of the preceding claims, characterized in that the wall section (10) delimits at least one compartment-like receptacle (53a, 53b, 53c). Method according to one of the preceding claims, characterized in that a film, in particular a deep-drawn film, is arranged in the lower tool before the foamed particles are introduced into the lower tool. Procedure according to Claim 8 , characterized by the step: k) applying a cover layer (28) to the side (27) of the particle foam (33) facing away from the film (21). Method according to one of the preceding claims, characterized by the step: I) processing of the molding. Procedure according to Claim 8 , characterized in that the film (21) has a wall thickness (W1) between 0.2 mm and 13 mm. Method according to one of the preceding claims, characterized in that the hardened particle foam (33) has a wall thickness (W2) between 1 cm and 30 cm. Method according to one of the preceding claims, characterized in that the starting material is provided from expandable EPS, PP, or PEEK. Method according to one of the preceding claims, characterized in that the following step is carried out before step iii) is carried out: m) positioning of insert elements (41), in particular reinforcement elements, in particular in the form of tie rods, for example in the form of tapes or in particular screw receptacles or of hinges or parts (41) of hinges, in the lower tool, wherein after the foamed particles (31a, 31b, 31c) have been introduced into the lower tool (23), these envelop the insert elements. Transport and / or storage container (37), in particular manufactured according to one of the preceding claims, characterized in that the transport and / or storage container has at least one wall section (10) which is provided by a cured particle foam (33). Transport and / or storage container according to Claim 15 , characterized in that the container (37) has at least one shell part (40a, 40b) which is designed in one piece and consists of a hardened particle foam. Transport and / or storage container according to Claim 15 or 16 , characterized in that the shell element (40a, 40b) comprises a storage compartment or accommodation compartment arrangement (53a, 53b, 53c) attached to the wall section in one piece with a material fit.

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