DE102020204876A1 - Method for producing a component comprising a rigid foam, as well as a device for carrying out the method and a motor vehicle - Google Patents

Abstract

The invention relates to a method for producing a component comprising a rigid foam, in particular a particle foam component for a motor vehicle, in which a cavity (10) is filled with a multiplicity of plastic bodies (100) and at least one wall (20, 30) which at least in sections forms a cavity boundary ) is heated at least in areas, heat is transferred from the wall (20, 30) to the plastic body (100) and the plastic body (100) is at least partially, in particular, due to the heat supplied via the wall (20, 30) essentially by means of thermal conduction at least on surface areas, and melt through the formation of cohesive connections between adjacent plastic bodies (100) to form an overall body. The invention also relates to a device (1) for carrying out the method according to the invention and to a motor vehicle.

Description

The invention relates to a method for manufacturing a component comprising a rigid foam, a device for performing the method for manufacturing a component comprising a rigid foam, and a motor vehicle comprising a component comprising a rigid foam manufactured according to the method according to the invention.

Components made from a rigid foam are particularly important in lightweight construction because of their low weight and high strength. Hard foam components, which are also referred to as particle foam components, are typically produced by introducing steam into a mold cavity filled with plastic bodies, so that the plastic bodies are heated and fuse to form a plastic body composite.

There is an effort to make such manufacturing processes as cost-effective as possible. In addition to process management, this also applies to the tools required to carry out such manufacturing processes.

It is customary to introduce the energy necessary for fusing the plastic bodies directly into the mold cavity by means of a gaseous heat transfer medium, the heat transfer medium typically being a water vapor.

The use of water vapor as a heat transfer medium to be fed directly into the cavity requires the tool to have high compressive strength. This typically also has an impact on tool costs. In such a variant of the method using steam, it is also technologically difficult to integrate electronic components into the rigid foam component without damaging them as a result of temperature and / or moisture.

Various methods and tools for producing particle foam components are known.

the DE 10 2015 013 131 A1 shows an example of such a tool and the associated method for producing a molded part consisting of a particle foam. The tool shown here consists of two tool halves, each with a steam chamber and a temperature control unit. The main purpose of the temperature control unit is to preheat the mold halves to the temperature of the superheated steam to be fed into the cavity, so that condensation of the superheated steam during the actual manufacturing process is avoided. Furthermore, after the filled plastic particles have melted or melted on caused by the superheated steam, the temperature control unit is used to cool the tool to a deformation temperature.

the WO 2016/083464 A1 shows a tool that also consists of two tool halves that form a cavity and each have a steam chamber which is set up to conduct water vapor through them. The walls delimiting the cavity have several openings which enable partial volume flows of the steam volume flows to penetrate into the cavity for the purpose of introducing energy to melt the particles which are filled into the cavity.

The present invention is based on the object of providing a method and a device which enable components comprising rigid foam to be produced efficiently and cost-effectively.

The object is achieved according to the invention by a method for producing a component comprising a hard foam according to claim 1. Furthermore, the object is achieved by a device for performing the method for producing a component comprising a hard foam according to claim 6 Subclaims 2-5 shown. Advantageous embodiments of the device according to the invention are shown in the subclaims 7-9. In addition, a motor vehicle, comprising a component comprising a rigid foam, produced according to the method according to the invention, is made available according to claim 10.

A first aspect of the invention is a method for producing a component comprising a rigid foam, in particular a particle foam component for a motor vehicle, in which a cavity is filled with a plurality of plastic bodies and at least one wall that forms a cavity boundary at least in sections is heated at least in regions. Heat is transferred from the wall to the plastic body, so that the plastic body, due to the heat supplied via the wall, essentially by means of thermal conduction, melts at least partially, in particular at least on surface areas, and connects to an overall body through the formation of material connections between adjacent plastic bodies.

In other words, the heat is only through one or more heated walls in the cavity and thus introduced into the mass of the plastic body. In contrast to the widespread methods for producing particle foam components, the invention does not provide for heat to be introduced into the cavity by supplying a heated or heated heat transfer medium, such as, for example, supplying steam.

The cavity to be filled with plastic bodies is a cavity of a device or a tool for carrying out the method according to the invention and usually corresponds essentially to the negative shape of the component to be produced. Typically, but not necessarily, the cavity is formed by two halves that can be or are connected to one another.

The cavity boundary, that is to say the boundary surface of the cavity which is filled with plastic bodies, is at least partially formed by at least one wall that can be heated. In other words, the wall has a side facing the cavity, which is at least a partial area of the cavity delimitation. The wall is heated in particular on a side facing away from the cavity, in particular the side opposite the side delimiting the cavity. The heat is transferred by means of heat conduction through the wall to the side delimiting the cavity and from here to the cavity or the plastic body located in the cavity.

In particular when using the method according to the invention for producing flat or essentially two-dimensional components, the plastic bodies in the cavity are advantageously heated by means of a plurality of heatable walls. The heatable walls are advantageously arranged opposite one another at least in some areas.

In the context of the invention, a rigid foam is a porous solid. In this case, gas-filled cavities, or also pores or bubbles, are present within the solid body. According to the invention, the rigid foam is formed in that plastic bodies are melted on at least in areas of their surface, so that plastic bodies that are adjacent to one another or that adjoin one another in areas are connected by a material mixing of their respective melts. This process is also known as sintering. In this case, cavities are at least partially retained between the plastic bodies.

Melting is to be understood as meaning that only partial areas, in particular only surface areas, are brought into a molten state. When melting, the solid melts particularly preferably just as much as is necessary to form material connections with the adjacent plastic bodies. Complete melting of the plastic bodies is typically not desired.

In principle, however, it cannot be ruled out that at least some of the plastic bodies melt completely in certain areas of the cavity.

In technical terms, corresponding plastic bodies are also referred to as particles, so that the component to be produced can also be referred to as a particle foam component. The plastic bodies usually have an average diameter of dp, where 0.5 mm <dp <10 mm. The outer shape of the particles can, if necessary, deviate significantly from a sphere. It is possible that the plastic bodies which are filled into the cavity are porous, i.e. already have an internal gas volume in the sense of pores before the method according to the invention is carried out. It can be provided that, due to the heating of the plastic body when carrying out the method according to the invention, the volume of individual plastic bodies increases due to an expansion of the gas inside the plastic body, so that the entire body essentially completely fills the cavity and / or at least partially is applied to the cavity boundary.

In one embodiment, the plastic bodies comprise, at least in some areas, a polycarbonate, a polyethylene terephthalate and / or so-called high-temperature materials, the melting temperature of which is in the upper range of the vapor pressure curve of water or above the vapor pressure curve of water. The method according to the invention can therefore also be used to process plastics for which a steam pressure above 20 bar would be required for melting.

The heat is transferred from the heated wall to the plastic body. The heat is supplied from the wall to the plastic body in the cavity essentially by means of heat conduction. However, it should not be ruled out that small proportions, i.e. less than 10%, in particular less than 5%, of the heat that is supplied is transferred by thermal radiation from the wall to the plastic body in the cavity.

The plastic body composite resulting from the melting to one another or the regional melting of the plastic bodies is the overall body. This is a hard foam in the sense of the above definition. The component to be produced can exclusively comprise the entire body. However, it is also possible that the The component to be produced includes further elements in addition to the overall body.

The advantage of the method according to the invention is that the plastic bodies located in the cavity are heated by heat conduction via a wall delimiting the cavity, so that the plastic bodies can fuse in certain areas.

A variant of the method according to the invention provides for components, in particular electronic components, to be introduced into the cavity in addition to the plastic bodies, so that a multi-component component comprising a rigid foam can be produced with the method according to the invention. The fact that water vapor is not fed into the cavity as a heat transfer medium makes this possible, since the method according to the invention does not use any steam that can damage the electronic components.

In another variant of the method according to the invention, it can alternatively or additionally be provided for mechanical stabilization elements to be introduced into the cavity in addition to the plastic bodies in order to increase the mechanical stability of the component to be produced, in particular in the case of essentially flat components to be produced and / or in the case of components to be produced with a complex three-dimensional design.

In one embodiment of the method according to the invention, the cavity is a closed space. The gas volume in the spaces between the plastic bodies is heated in the cavity exclusively via the wall.

The cavity is a space that is at least partially gas-tight, so that no gas, in particular no steam, penetrates into the cavity during the manufacturing process, in particular during the heating of the plastic body. In other words, after the cavity has been filled with the plastic bodies and during the formation of the integral connection between the plastic bodies, essentially no gas, in particular no heated gas and / or steam, penetrates the cavity. It cannot be ruled out that, due to an increase in pressure in the cavity, gas can escape from the cavity. Of course, the cavity has at least one closable opening that allows the plastic body to be filled. Furthermore, the cavity is to be opened to the extent that the component to be produced can be removed. Correspondingly, the cavity has at least one sealing device for the purpose of realizing the at least partial gas tightness while the method according to the invention is being carried out.

The gas volume in the spaces between the plastic bodies is heated in the cavity exclusively via the wall. The heat transfer and / or the heat distribution within the cavity in the spaces between the plastic bodies takes place essentially via convection, i.e. the movement of molecules in the gas space that carry thermal energy in the gas phase of the spaces between the plastic bodies. The plastic bodies are at least partially heated convectively by the heated gas phase. A heat transfer by conduction between adjacent plastic bodies in areas in contact with one another can also take place.

The advantage of this embodiment is that the device can be designed with a correspondingly low structural effort.

In one embodiment of the method according to the invention, plastic bodies are melted on at least a partial area of at least one wall, so that a cohesive, in particular adhesive, connection is formed between the entire body and the partial area of the wall for the purpose of producing a composite component comprising the entire body and the partial area of the wall.

In other words, with this variant of the method it is possible to produce a composite component, a component component of the composite component being at least a portion of a heatable wall and at the same time a shaping element for the entire body when the method according to the invention is carried out. After the method according to the invention has been carried out, at least this partial area of the wall is removed together with the entire body as a composite component of the device set up for the method according to the invention.

The connection between the partial area of the wall and the entire body, that is to say the rigid foam, is an integral connection, in particular an adhesive connection. In other words, the entire body and partial area of the wall adhere to one another. It is not excluded that a substance supporting the formation of an integral connection is or is arranged on the side of the partial area of the wall facing the cavity.

In this embodiment of the method according to the invention, it is timed before the filling of the cavity with the plastic bodies, the partial area of the wall, which is part of the composite component to be produced, is arranged in and / or on the cavity.

In an alternative embodiment, the entire body does not adhere to any part of the wall and / or to any part of the cavity boundary. In this case, the component can also be understood as a blank, which can be combined with other components in the course of further processing.

In order to prevent the entire body from adhering to the cavity delimitation or to the wall, the cavity delimitation or the wall can be provided with a release agent and / or a release layer or release coating on its side facing the cavity, at least in some areas. This embodiment facilitates the demolding of the component to be produced using the method according to the invention, with demolding in the sense of the invention being understood to mean any detachment of the component from and / or removal of the component from the cavity.

In one embodiment of the method according to the invention, after the heating of the wall to transfer heat to the plastic body for the purpose of melting the plastic body, the wall is cooled for the purpose of cooling the plastic body.

In other words, in a first method step, the plastic bodies are heated and connected to one another for the purpose of forming the entire body. After that, in a second process step, the plastic bodies, or the entire body that has now been produced, are cooled. In particular, the plastic bodies are cooled in an edge region of the cavity adjoining the wall. Advantageously, essentially all of the plastic bodies, or the entire body as a whole, are cooled during the cooling process. The cooling serves on the one hand to stop the introduction of heat into the mass of the plastic body and thus the process of melting on, so that in this way a complete melting of the plastic body is prevented. On the other hand, the cooling, which is typically accompanied by a certain shrinkage of the component, serves to demold the component comprising the rigid foam and to separate it from the boundary of the cavity.

In one embodiment of the method according to the invention, the wall to be heated is heated by contacting a side of the wall essentially opposite the cavity with an, in particular liquid, temperature control medium.

In a further embodiment, the wall is cooled temporally after the heating of the wall by contacting a side of the wall essentially opposite the cavity with a, in particular liquid, temperature control medium.

In other words, the method can comprise two method steps. In a first method step, a heated, in particular liquid, temperature control medium is supplied to a side of the wall that is essentially opposite the cavity. The heat of the temperature control medium is transferred to the wall and from the wall to the plastic body by conduction. In a second method step, a cold, in particular liquid, temperature control medium is supplied to a side of the wall that is essentially opposite the cavity, so that, in reverse, heat is transferred from the plastic bodies via the wall to the temperature control medium. While the aim of the first process step is to melt the plastic body, the second process step has the aim of stopping the melting of the plastic body so that the plastic body is prevented from completely melting and / or the component to be produced is removed from the mold.

The first and the second temperature control medium can basically be essentially the same with regard to their material composition and only have a different temperature. However, it is also possible for two different temperature control media to be provided and / or generated, one of which is a heating medium and one of which is a cooling medium.

The temperature control medium is in particular a liquid. Typically this is water, oil or a water-oil mixture. If the temperature control medium is a cooling medium, it can alternatively or additionally contain a gas such as CO2. The use of natural refrigerants as a substitute for fluorinated greenhouse gases, so-called F-gases, should be taken into account.

In a further embodiment of the method according to the invention, a side of the wall essentially opposite the cavity is exposed to temperature control media volume flows in different areas, at least two of the volume flows having different flow directions, temperatures and / or flow velocities.

Typically, but not necessarily, the at least two temperature control media volume flows are im with respect to their flow direction Aligned essentially parallel to each other. The volume flows can have the same direction of flow. In principle, however, it is also possible for the temperature control medium volume flows to have flow directions opposite one another.

The use of several temperature control media volume flows for heating and / or cooling the wall has the advantage that the temperature of the wall, and thus the heat transfer into the plastic body, can be designed differently in certain areas. On the one hand, this embodiment can be used to achieve essentially the same temperature in essentially all areas of the wall, i.e. a temperature distribution with temperature differences of typically less than 5 ° C. This embodiment of the method is particularly advantageous for the production of flat components with an overall body with essentially the same overall body density regardless of the area. The density of the entire body depends on how strongly the plastic bodies are fused together. The more heat is introduced, the more the plastic bodies fuse, which leads to an increase in the density of the entire body. Consequently, an even distribution of heat during the manufacturing process results in an even distribution of total body density.

On the other hand, this embodiment can be used to set specific temperature differences in a targeted manner by means of the physical parameters of flow direction, temperature and / or flow speed of the tempering medium volume flows. The latter is particularly advantageous in the production of so-called components comprising integral foams, that is to say components whose overall body comprises a rigid foam with at least regionally decreasing or increasing density.

The temperature control media volume flows can differ with regard to several of the physical parameters of flow direction, temperature and / or flow speed.

In a further embodiment of the method according to the invention, the temperature control medium flows through a cavity delimited by the wall on the side opposite the cavity, wherein the temperature of the temperature control medium in a temperature control medium inlet area of the cavity T _E corresponds to the temperature of the temperature control medium in a temperature control medium outlet area of the cavity T _{A has} a difference of T _E -T _A <10 ° C, in particular of T _E -T _A <5 ° C.

A second aspect of the invention is a device for carrying out the method according to the invention, comprising a cavity which can be filled with a multiplicity of plastic bodies and has a cavity boundary formed at least in sections by at least one wall. The wall can be heated, so that heat can be transferred from the wall to the plastic body and, due to the heat supplied via the wall essentially by means of heat conduction, the plastic body can at least partially melt, in particular at least on surface areas, and form material connections between can connect adjacent plastic bodies to form a total body.

In particular, the device comprises at least two tool halves which are at least partially separable from one another so that the component to be produced can be removed after the method according to the invention has been carried out.

For the purpose of filling the cavity, the device comprises at least one plastic body feed.

In one embodiment of the device according to the invention, the heatable wall is formed at least in sections from a material with a thermal conductivity of at least 120 W / (m K).

In particular, the thermal conductivity is at least 240 W / (m K). In a particular embodiment, the thermal conductivity is at least 480 W / (m K).

Typically, but not necessarily, the wall is essentially formed from a metal. In an advantageous embodiment of the device according to the invention, the wall is formed by a sheet metal part, the cavity-delimiting side of the sheet metal part, which is shaping for the component to be produced, at least in some areas in terms of shape and size corresponds to a motor vehicle component on which the component to be produced using the method according to the invention is in finished motor vehicle should be applied at least in some areas.

In a particularly advantageous embodiment of the device, the shaping, heatable wall is exchangeable, so that the device is set up so that it can be used to produce several different components comprising a rigid foam.

In a further embodiment of the device according to the invention, the heatable Wall has a maximum thickness Dw, where Dw <5 mm.

In particular, the maximum thickness Dw is <3 mm. In a particular embodiment, the maximum thickness Dw is <1 mm.

The heatable wall has a first side facing the cavity and a side opposite the first side. The two sides are advantageously substantially equally spaced from one another in all areas. In other words, the wall has essentially the same thickness Dw in all areas. This means that the wall can be made very thin and consequently can be manufactured cost-effectively.

In a further embodiment of the device according to the invention, the cavity is designed as a negative shape of an essentially flat component with a base area and a top surface opposite the base area. _{The cavity has a vertical extension D K} between a side assigned to the base area and a side assigned to the top area, where 2 mm <D _K > 30 mm.

The base surface and the top surface of the component to be produced are typically, but not necessarily, aligned parallel to one another at least in sections. The vertical extension D _K can also be referred to as the clearance height of the cavity. In other words, the device is set up to process components with a component thickness of at least 2 mm and at most 25 mm, in particular at least 6 mm and at most 20 mm. In a particular embodiment, the component thickness is at least 6 mm and at most 12 mm.

In a further embodiment of the device according to the invention, the heatable wall is at least partially gas-tight. In other words, this means that the wall does not have any recesses, perforations, flaws, passages or such openings which allow the temperature control medium to penetrate into the cavity and / or onto the plastic body.

Furthermore, the cavity is designed as an at least partially gas-tight space. In particular, the plastic body feed, for introducing the plastic body into the cavity, and / or the removal opening, for removing the manufactured component, can be closed by means of sealing devices in such a way that no gas can enter the cavity. It is possible, but not absolutely necessary, for the cavity to be closable in a gas-tight manner in such a way that no gas can escape from the cavity.

In one embodiment of the device according to the invention, the boundary of the cavity has at least one recess in which a shaping element, in particular a shaping element made of a metal, can be arranged, which when arranged in the recess forms a partial area of the cavity boundary.

The shaping element can be a component of a composite component which can be produced by means of the method according to the invention in such a way that plastic bodies melt onto the shaping element. The shaping element and overall body can be removed from the cavity in this embodiment as a composite component.

The shaping elements can be taken from the prototype construction as an example. The shaping elements represent the topography of the vehicle component adjoining the component to be produced.

The shaping element can be a partial area of the wall that can be heated.

The advantage of this embodiment is that the device is suitable for producing composite components comprising rigid foam.

In one embodiment of the device according to the invention, at least one cavity for receiving at least one temperature control medium, in particular for the flow of at least one temperature control medium, is arranged on at least a partial area of the side of the wall facing away from the cavity.

The cavity is advantageously designed to have at least one temperature control medium flowing through it. The temperature control medium flows along the heatable wall. In particular, the cavity is designed to accommodate at least two temperature control media and / or to have at least two temperature control media flow through it, namely a warm temperature control medium for heating the wall and a cold temperature control medium for cooling the wall.

The device according to the invention is particularly designed so that a warm temperature control medium and a cold temperature control medium flow through the cavity one after the other, with a simultaneous flow of a warm temperature control medium and a cold temperature control medium at times being not excluded.

In particular in an embodiment of the device according to the invention for producing flat components, the device advantageously comprises at least two cavities, which are particularly advantageously arranged opposite one another.

In a further embodiment of the device according to the invention, the cavity has an extension of D _T perpendicular to the side of the heatable boundary wall facing away from the cavity, where 1 mm <D _T <80 mm.

The vertical extension D _T can also be referred to as the clear height of the cavity. In other words, the cavity is designed as a layer-like cavity adjoining the cavity at least in sections for receiving a temperature control medium with a maximum clear height of 80 mm and a minimum clear height of 1 mm. The vertical extent D _T is advantageously essentially the same in all areas of the cavity, so that when the temperature control medium flows through the cavity, essentially the same flow rate of the temperature control medium can be achieved in all areas.

In a further embodiment of the device according to the invention, the vertical extension of the cavity D _T and the vertical extension of the cavity D _{K have} a ratio of D _K / D _T , where D _K / D _T > 1.

In other words, the ratio of the clear height of the cavity to the clear height of the cavity that can be filled with temperature control medium is at least 1.

The cavity can, for example, be delimited at least in sections by two sheet-metal parts which are arranged parallel to one another, in particular topographically identical. In this way, a constant clear height of the cavity, and thus a constant thickness of the layer of the temperature control medium, can be achieved.

In a further embodiment of the device according to the invention, the cavity has flow guide devices for the purpose of substantially uniform heating of the wall.

In a first specific embodiment, the device according to the invention has a flow guide device in the form of a distributor device for distributing the temperature control medium in the cavity, in particular when the temperature control medium flows into the cavity in a temperature control medium inlet region of the cavity. Advantageously, the distribution device is designed to divide a total volume flow of a temperature control medium into partial volume flows, in particular essentially equal partial volume flows, and to allow these to flow into the cavity at an essentially equidistant distance transversely to the flow direction of the temperature control medium through the remaining cavity. Typically, the partial volume flows are combined in a temperature control media outlet area of the cavity with a collector device to form a total volume flow, in order to be fed to a processing device if necessary. The temperature control medium advantageously flows out of the cavity from a temperature control medium outlet area in equidistantly spaced partial volume flows.

In a second specific embodiment, the device according to the invention alternatively or additionally has flow guiding devices in the form of separating devices which are set up to direct the total volume flow of the temperature control medium in substantially separate partial volume flows over the heatable wall. Such a separating device can be designed, for example, by means of tubes which are aligned parallel to the direction of flow and which are arranged in the interior of the cavity. It is also possible to arrange partition plates aligned parallel to the direction of flow in the cavity for the purpose of forming channels. It is not absolutely necessary, but possibly an advantage, that the partial volume flows do not mix while flowing through the cavity.

In addition to the division of a total volume flow into several partial volume flows, which have essentially the same physical parameters at least when flowing into the cavity, it is also possible to allow different temperature control media to flow into the cavity, which can be at least one physical parameter, such as temperature and / or flow velocity, differentiate. In this way it is possible to realize a temperature distribution in the cavity transversely to the direction of flow, so that a component to be produced can be heated to a greater or lesser extent in some areas, and thus integral foam components can be produced with the device according to the invention.

In a third specific embodiment, the device according to the invention alternatively or additionally has flow guiding devices in the form of swirling elements, which are set up to at least partially swirl the total volume flow of the temperature control medium inside the cavity, so that essentially the same at least transversely to the flow direction of the temperature control medium Temperature in the cavity is realizable. In a particularly simple and effective manner, turbulence elements can be implemented as webs in the cavity that are oriented perpendicular to the wall.

Different types and configurations of flow guide devices can in principle be combined.

In a further embodiment of the device according to the invention, mechanical stabilization elements are arranged in the interior of the cavity for the purpose of regionally stiffening the device, so that deformation of the cavity, in particular due to pressure from the entire body on the wall, can be prevented.

In a further embodiment of the device according to the invention, the cavity and / or hollow space are at least partially surrounded by an insulating material, in particular a material comprising a polymer concrete and / or a thermosetting composite material, in order to minimize heat losses.

A third aspect of the invention is a motor vehicle, in particular a passenger car, comprising at least one component manufactured according to the method according to the invention for manufacturing a component comprising a rigid foam.

The invention is explained below with reference to the exemplary embodiments shown in the accompanying drawings.

• 1: eine Ausgestaltungsform der erfindungsgemäßen Vorrichtung zur Durchführung des erfindungsgemäßen Verfahrens zur Herstellung eines einen Hartschaum umfassenden Bauteils;
• 2: einen Ausschnitt der Ausführungsform gemäß 1;
• 3.: eine Ausgestaltungsform eines Hohlraums der erfindungsgemäßen Vorrichtung in einer Draufsicht auf den Hohlraum;
• 4: eine erste Ausgestaltungsform des Hohlraums gemäß 3 im Schnitt A-A;
• 5: eine zweite Ausgestaltungsform des Hohlraums gemäß 3 im Schnitt A-A;
• 6: eine dritte Ausgestaltungsform des Hohlraums gemäß 3 im Schnitt A-A;
• 7.: eine weitere Ausgestaltungsform eines Hohlraums der erfindungsgemäßen Vorrichtung in einer Draufsicht auf den Hohlraum; sowie
• 8: eine Ausgestaltungsform des Hohlraums gemäß 7 im Schnitt A-A.

Show it

• 1 : an embodiment of the device according to the invention for carrying out the method according to the invention for producing a component comprising a rigid foam;
• 2 : a section of the embodiment according to FIG 1 ;
• 3 .: an embodiment of a cavity of the device according to the invention in a plan view of the cavity;
• 4th : a first embodiment of the cavity according to FIG 3 in section AA;
• 5 : a second embodiment of the cavity according to FIG 3 in section AA;
• 6th : a third embodiment of the cavity according to FIG 3 in section AA;
• 7th .: Another embodiment of a cavity of the device according to the invention in a plan view of the cavity; as
• 8th : an embodiment of the cavity according to 7th in section AA.

1 shows an embodiment of the device according to the invention 1 for carrying out the method according to the invention for producing a component comprising a rigid foam.

The device 1 has tool upper part 50 and a tool base 52 working at the tool division 51 are at least partially separable, so that the device 1 opened and the component produced from the cavity 10 can be taken. In the example shown, the device is 1 set up to produce an essentially flat component. It can be seen that the device 1 has a structure in several levels.

One cavity 10 is on its top and its bottom by a heatable first wall 20th and a heatable second wall 30th limited. When carrying out the method according to the invention for producing a component comprising a rigid foam, the cavity 10 initially via the plastic body feed 11 , which can also be called an injector, with plastic bodies 100 filled. Is the cavity 10 sufficiently filled, the plastic body feeder is 11 locked. The cavity 10 is set up to form a gas-tight space, which means that in particular over the first wall 20th and the second wall 30th neither gas, vapor nor liquid into the cavity 10 can penetrate.

Then the first cavity 21 and the second cavity 31 with a typically liquid temperature control medium flowing through it, which by means of a temperature control module 40 tempered and via the tempering medium inlet 41 the cavities 21 , 31 is fed.

In the first process step, the cavities 21 , 31 flowed through with a warm temperature control medium. The heat of the temperature control medium is transferred to the cavity via thermal conduction 10 and the one in the cavity 10 located plastic body 100 released, whereupon these melt and form an overall body. In the second process step, the cavities 21 , 31 with a cold temperature control medium flowing through it to the walls 20th , 30th to cool and the melting and / or fusing of the plastic body 100 to stop. The temperature control module 40 is set up in the example shown to provide both a warm and a cold temperature control medium. During the melting of the Plastic body 100 a heat transfer medium, in particular no steam, is neither active nor passive into the cavity 10 initiated.

The temperature control medium flows over the temperature control medium drain 45 from the cavities 21 , 31 and is sent to processing. After the two walls have cooled down sufficiently 20th , 30th or the plastic body fused to form an overall body 100 in the cavity 10 become the upper part of the tool 50 and the lower part of the tool 52 at least partially separated from one another so that the component can be removed.

2 shows a section of the in 1 embodiment shown. It can be seen that the cavities 21 , 31 each from two sheet metal parts 35 are limited. These sheet metal parts, which are shaping for the component to be produced, are advantageously sheet metal parts of the type on which the component to be produced is to be arranged in the vehicle. In one embodiment it is provided that the plastic body 100 with which the cavity 10 is filled, to one of the cavity 10 limiting first page 12th one wall 20th , 30th melt, so that a material connection between a wall 20th , 30th and the plastic bodies 100 is formed and a composite component comprising the entire body and at least one of the two walls 20th , 30th can be produced. The first page 12th opposite is the second side 13th the respective wall 20th , 30th arranged, which the respective cavity 21 , 31 towards the cavity 10 limited. In the embodiment shown, the sheets are 35 arranged in such a way that the respective lower and upper sides are aligned with one another as parallel surfaces. In this way, a structure of the device is implemented in several levels, the spacing of the levels from one another, that is to say the cavities 21, 31 and the cavity 10 , is essentially the same in all areas.

In order to minimize heat loss, the sheets are 35 at least partially surrounded by insulation. The device can be designed so that different sheet metal parts 35 in the upper part of the tool 50 and the lower part of the tool 52 can be introduced. In this way, the device can be used flexibly for different components to be produced.

A plastic body feed can also be seen in this section 11 .

3 shows an embodiment of the first cavity 21 the device according to the invention in a sectional plan view of the first cavity 21 . The second cavity 31 can be designed in a comparable way. It can be seen that the temperature control medium 47 by means of a distribution device 42 the cavity 21 is supplied in such a way that the total volume flow is divided into several partial volume flows, with the respective inlet areas in the cavity 21 are substantially equally spaced from one another. Inside the cavity 21 are dividing devices 25th arranged, which enable several partial volume flows of the temperature control medium 47 can be guided separately from one another and parallel to one another over the walls. The dividing devices 25th can be designed in different ways. After flowing through the cavity 21 becomes the temperature control medium 47 by means of a collector device 46 merged again into a volume flow, which is fed to a processing device, which is not shown here.

4th shows an example of a first embodiment of the cavity 21 in a section along the course AA according to 3 . Between the cavity-delimiting first side 13th and the cavity defining second side 14th are dividing elements 48 arranged in such a way that channels with a triangular cross section are formed through which the temperature control medium 47 flows.

5 shows in an analogous way to 4th a second embodiment of the cavity 21 in a section along the course AA according to 3 . Between the cavity-delimiting first side 13th and the cavity defining second side 14th are also separating elements here 48 arranged. In this case, the separators 48 trapezoidal channels through which the temperature control medium 47 flows.

Again shows in an analogous manner 6th a third embodiment of the cavity 21 in a section along the course AA according to 3 . Between the cavity-delimiting first side 13th and the cavity defining second side 14th here are pipes 49 arranged. The pipes 49 are of the temperature control medium 47 flows through.

7th shows in a comparable way to 3 an embodiment of a cavity 21 the device according to the invention in a sectional plan view of the cavity. Here, too, is the temperature control medium 47 by means of a distribution device 42 in several partial volume flows the cavity 21 supplied and after flowing through the cavity 21 by means of a collector device 46 reunited into one volume flow. In contrast to the in 3 The embodiment shown are in this case vertically aligned webs 60 in the cavity 21 arranged, which are set up to cause a turbulence in the temperature control medium and thus a uniform temperature distribution in the cavity.

8th shows an example of an embodiment of the cavity 21 in a section along the course AA according to 7th . You can see the arrangement of the bars 60 between the void-defining first side 13th and the cavity defining second side 14th . Depending on the specific design, the webs 60 , as well as the dividing devices in 3 fulfill a mechanical stabilization function. Alternative to the bars 60 a variety of other turbulators can be used between the cavity-defining first side 13th and the cavity defining second side 14th to be ordered.

List of reference symbols

1

contraption

10

cavity

11

Plastic body feeder

12th

First side delimiting the cavity

13th

cavity-delimiting second side

14th

void-delimiting first side

20th

First wall

21

First cavity

25th

Dividing device

30th

Second wall

31

Second cavity

35

Sheet metal part

40

Temperature control module

41

Tempering medium supply

42

Distribution device

45

Temperature control media drain

46

Collector facility

47

Temperature control medium

48

Separator

49

pipe

50

Tool head

51

Tool division

52

Tool lower part

60

web

100

Plastic body

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 102015013131 A1 [0007]
• WO 2016/083464 A1 [0008]

Claims (10)

A method for producing a component comprising a rigid foam, in particular a particle foam component for a motor vehicle, in which a cavity (10) is filled with a multiplicity of plastic bodies (100) and at least one wall (20, 30) that forms a cavity boundary at least in sections is heated at least in regions and in which heat is transferred from the wall (20, 30) to the plastic body (100) and the plastic body (100) is at least partially, in particular at least partially, due to the heat supplied via the wall (20, 30) essentially by means of thermal conduction on surface areas, melt and connect through the formation of material connections between adjacent plastic bodies (100) to form an overall body. Method for producing a component comprising a rigid foam according to Claim 1 , characterized in that the cavity (10) is a closed space and the gas volume in the spaces between the plastic bodies (100) in the cavity (100) is heated exclusively via the wall (20, 30). Method for producing a component comprising a rigid foam according to one of the preceding claims, characterized in that plastic bodies (100) are melted on at least a partial area of at least one wall (20, 30) so that a cohesive, in particular adhesive, connection between the overall body and the partial area of the wall (20, 30) is formed for the purpose of producing a composite component comprising the entire body and the partial area of the wall (20, 30). Method for producing a component comprising a rigid foam according to one of the preceding claims, characterized in that after the heating of the wall (20, 30) for the transfer of heat to the plastic body (100) for the purpose of melting the plastic body (100), the wall is cooled (20, 30) takes place for the purpose of cooling the plastic body (100). Method for the production of a component comprising a rigid foam according to one of the preceding claims, characterized in that the wall (20, 30) to be heated by contacting a side (13) of the wall (20, 30) substantially opposite the cavity (10) a, in particular liquid, temperature control medium (47) is heated. Device (1) for carrying out the method for producing a component comprising a rigid foam according to one of the Claims 1 - 5 , comprising a cavity (10) which can be filled with a multiplicity of plastic bodies (100) and has a cavity boundary formed at least in sections by at least one wall (20, 30), the wall (20, 30) being heatable so that the wall (20 , 30) heat is transferred to the plastic body (100) and the plastic body (100) due to the heat supplied via the wall (20, 30) essentially by means of heat conduction at least partially, in particular at least on surface areas, melt and through the formation of cohesive Connect connections between adjacent plastic bodies (100) to form an overall body. Device (1) for carrying out the method for producing a component comprising a rigid foam according to Claim 6 , characterized in that the heatable wall (20, 30) is formed at least in sections from a material with a thermal conductivity of at least 120 W / (m K). Device (1) for performing the method for producing a component comprising a rigid foam according to one of the Claims 6 - 7th , characterized in that the delimitation of the cavity (10) has at least one recess in which a shaping element, in particular a shaping element made of a metal, can be arranged which, when arranged in the recess, forms a portion of the cavity delimitation. Device (1) for performing the method for producing a component comprising a rigid foam according to one of the Claims 6 - 8th , characterized in that on at least a partial area of the side (13) of the wall (20, 30) facing away from the cavity (100) at least one cavity (10) for receiving at least one temperature control medium (47), in particular for the flow of at least one temperature control medium ( 47), is arranged. Motor vehicle, in particular passenger car, comprising at least one component manufactured according to the method for manufacturing a component comprising a rigid foam according to one of the Claims 1 - 5 .

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