DE202022102279U1 - Mold for producing a molded component from a mat-shaped blank made of a compressible plastic material - Google Patents

Abstract

Tool half (3) for producing a molded component (2) from a mat-shaped blank made of a compressible plastic material, in particular a blank made of connected plastic threads, preferably made of polyethylene
- A receiving element (4) for shaping the mat-shaped blank into a body (5) of the molded component (2); and
- A frame element (6) which surrounds the receiving element (4) at its opening (7) to form a peripheral flange (8) for shaping the mat-shaped blank into a collar (9) of the molded component (2); whereby
- The receiving element (4), the frame element (6) are held together; the tool half (3) being characterized in that
- The receiving element (4) and the frame element (6) are thermally decoupled; and
- A temperature control line (12) is formed in the frame element (6) and extends between two temperature control medium connections (13).

Description

• - einem Aufnahmeelement zur Formgebung des mattenförmigen Rohlings zu einem Körper des Formbauteils; und
• - einem Rahmenelement, welches das Aufnahmeelement an dessen Öffnung unter Ausbildung eines umlaufenden Flansches zur Formgebung des mattenförmigen Rohlings zu einem Kragen des Formbauteils umgibt; wobei
• - das Aufnahmeelement und das Rahmenelement gemeinsam gehalten sind.

The present invention relates to a tool half for producing a molded component from a mat-shaped blank made of a compressible plastic material, in particular a blank made of connected plastic threads, preferably made of polyethylene

• - A receiving element for shaping the mat-shaped blank into a body of the molded component; and
• - A frame element which surrounds the receiving element at its opening to form a peripheral flange for shaping the mat-shaped blank to form a collar of the molded component; whereby
• - The receiving element and the frame element are held together.

• - zwei oben angegebenen Werkzeughälften, die korrespondierende Aufnahmeelemente und korrespondierende Rahmenelemente zur gemeinsamen Formgebung des Formbauteils aufweisen; wobei
• - die zwei Werkzeughälften zwischen einem geöffneten Zustand und einem geschlossenen Zustand bewegbar sind;
• - in dem geöffneten Zustand der mattenförmige Rohling zwischen den zwei Werkzeughälften positionierbar ist;
• - in dem geschlossenen Zustand der mattenförmige Rohling teilweise von den korrespondierenden Aufnahmeelementen zur Bildung eines Körpers des Formbauteils umschlossen ist und teilweise zwischen den korrespondierenden Flanschen der Rahmenelemente zu einem Kragen des Formbauteils verpressbar ist.

The present invention also relates to a mold for producing a molded component from a mat-shaped blank made of a compressible plastic material, in particular a blank made of connected plastic threads, preferably made of polyethylene

• - Two tool halves specified above, which have corresponding receiving elements and corresponding frame elements for the joint shaping of the mold component; whereby
• - the two mold halves are movable between an open condition and a closed condition;
• - In the open state, the mat-shaped blank can be positioned between the two tool halves;
• - In the closed state, the mat-shaped blank is partially enclosed by the corresponding receiving elements to form a body of the molded component and can be partially pressed between the corresponding flanges of the frame elements to form a collar of the molded component.

The present invention also relates to a molded component made from a mat-shaped blank made from a compressible plastic material, in particular a blank made from connected plastic threads, preferably made from polyethylene, which is produced using the above mold.

Various types of molded components which are produced in a similar manner are known from the prior art. These molded components are, in particular, what are known as slosh pads, which are used in liquid containers, particularly in moving objects such as vehicles, in order to reduce sloshing noises from a liquid in the liquid container. The idea is that the liquid has to move through the slosh pad, reducing its mobility and therefore sloshing, and as a result less sloshing noise. Such molded components are produced, for example, from a mat-shaped blank made from a compressible plastic material.

There are often high requirements for the use of such slosh pads, so that no contamination of the liquid in the liquid container can occur through the molded components. In the case of a fuel tank, for example, such contamination could result in the contamination entering the combustion chamber of the engine and causing serious damage there.

It is therefore important for these molded components to have good cohesion on the one hand and good permeability for the corresponding liquid on the other hand, in order to be able to counteract the sloshing of the liquid. For this purpose it is known, for example, to provide the mat-shaped blank from PE-HD threads (PE: polyethylene) and to form molded components with individual geometries from them. The threads can be present in the mat-shaped blank as a knitted or knitted fabric or in some other way and are preferably connected to one another. The production should take place in such a way that the molded components have a surface structure with good cohesion, i.e. that the threads do not tear and are held together as firmly as possible. In addition, easy handling should be made possible in order to be able to remove the molded components produced from the tool easily and with little effort. To this end, it has proven to be advantageous to produce the molded components with a peripheral, closed collar. The collar increases cohesion without compromising permeability.

A tool for producing such molded components from a mat-shaped blank comprises a mold plate with cavities formed therein which define the shapes of the molded components to be produced. The mold plate is mounted on a tool base plate and acts on a mat section with another mold plate by means of pressure and temperature. One challenge is to temper the mold plate. For this purpose, channels are typically milled into the mold plate circumferentially around the cavities in order to be able to carry out temperature control, particularly in the area of the collar. The channels are closed by a cover plate and sealed with a gasket.

This production is very complex, not very flexible and also involves a high risk of leaks due to the seals, which can be very long as sealing cords, for example.

Proceeding from this, the object of the present invention is to reduce the outlay for the construction of tools for the production of such molded components and the production of such molded components, and to avoid the risk of malfunctions, for example due to leaks, during production. In addition, it is desirable to increase the flexibility in the production of the molded components and to ensure reliable production of the molded components.

The object on which the present invention is based is achieved by a tool half having the features of claim 1 . Advantageous configurations of the tool half are described in the claims dependent on claim 1.

• - einem Aufnahmeelement zur Formgebung des mattenförmigen Rohlings zu einem Körper des Formbauteils; und
• - einem Rahmenelement, welches das Aufnahmeelement an dessen Öffnung unter Ausbildung eines umlaufenden Flansches zur Formgebung des mattenförmigen Rohlings zu einem Kragen des Formbauteils umgibt; wobei
• - das Aufnahmeelement und das Rahmenelement gemeinsam gehalten sind;

gelöst. More precisely, the object on which the present invention is based is achieved by a tool half for producing a molded component from a mat-shaped blank made of a compressible plastic material, in particular a blank made of connected plastic threads, preferably made of polyethylene

• - A receiving element for shaping the mat-shaped blank into a body of the molded component; and
• - A frame element which surrounds the receiving element at its opening to form a peripheral flange for shaping the mat-shaped blank to form a collar of the molded component; whereby
• - the receiving element and the frame element are held together;

solved.

• - das Aufnahmeelement und das Rahmenelement thermisch entkoppelt sind; und
• - in dem Rahmenelement eine Temperierungsleitung ausgebildet ist, die sich zwischen zwei Temperierungsmittelanschlüssen erstreckt.

The tool half according to the invention is characterized in that

• - The receiving element and the frame element are thermally decoupled; and
• - A temperature control line is formed in the frame element, which extends between two temperature control medium connections.

The object on which the present invention is based is also achieved by a mold having the features of claim 9 . Advantageous configurations of the mold are described in the claims dependent on claim 9.

• - zwei oben angegebenen Werkzeughälften, die korrespondierende Aufnahmeelemente und korrespondierende Rahmenelemente zur gemeinsamen Formgebung des Formbauteils aufweisen; wobei
• - die zwei Werkzeughälften zwischen einem geöffneten Zustand und einem geschlossenen Zustand bewegbar sind;
• - in dem geöffneten Zustand der mattenförmige Rohling zwischen den zwei Werkzeughälften positionierbar ist;
• - in dem geschlossenen Zustand der mattenförmige Rohling teilweise von den korrespondierenden Aufnahmeelementen zur Bildung eines Körpers des Formbauteils umschlossen ist und teilweise zwischen den korrespondierenden Flanschen der Rahmenelemente zu einem Kragen des Formbauteils verpressbar ist.

More precisely, the object on which the present invention is based is also achieved by a mold for producing a molded component from a mat-shaped blank made of a compressible plastic material, in particular a blank made of connected plastic threads, preferably made of polyethylene

• - Two tool halves specified above, which have corresponding receiving elements and corresponding frame elements for the joint shaping of the mold component; whereby
• - the two mold halves are movable between an open condition and a closed condition;
• - In the open state, the mat-shaped blank can be positioned between the two tool halves;
• - In the closed state, the mat-shaped blank is partially enclosed by the corresponding receiving elements to form a body of the molded component and can be partially pressed between the corresponding flanges of the frame elements to form a collar of the molded component.

The object on which the present invention is based is additionally achieved by a molded component having the features of claim 12 .

More specifically, the object on which the present invention is based is additionally achieved by a molded component made of a mat-shaped blank made of a compressible plastic material, in particular a mat-shaped blank made of connected plastic threads, preferably made of polyethylene.

The molded component according to the invention is characterized in that it is produced with the molding tool specified above.

The tool half according to the invention and the mold with the two tool halves enable the molded component according to the invention to be produced efficiently, inexpensively and reliably. By separating the receiving member to form the body of the molded component and the frame member to form the collar of the molded component, both parts of the molded component can be manufactured efficiently. It is important for the production of the body of the molded component that it can be shaped uniformly in the receiving element with a surface structure with good cohesion, so that, for example, threads of the mat-shaped blank do not tear and are held together firmly overall without the surface for example melts and becomes impermeable to liquids. Temperature fluctuations in the area of the receiving element for shaping the body can thus be largely avoided, as can excessive heating. At the same time, the frame element can be reliably tempered, so that it can be manufactured with good tempering and reliability. The mat-shaped blank can be heated in the area of the collar via the frame element, as a result of which reliable fusion is made possible. The collar is strengthened by cooling via the frame element, so that the collar already has a high structural integrity when the mold is opened and splitting of the collar is avoided. The thermal separation between the receiving element and the frame element makes it possible to combine these two requirements, so that tempering the frame element has little or no influence on the temperature of the receiving element. A high degree of process reliability can be achieved, so that the molded components can be produced with a consistently high quality. A “tearing open” of the molded components, for example along the surface of the body or also in the transition area from the body to the collar, can be avoided. At the same time, the production time can be reduced in that the production of the collar is accelerated by the temperature control. The temperature of the frame element is controlled via the temperature control line formed therein, without the temperature of the receiving element being controlled. The separate provision of the receiving element and the frame element also results in a high level of flexibility in production, since the cost of designing and manufacturing the tool halves and the mold can be limited, since the receiving elements and frame elements are easier to produce individually than together. The provision of individual frame elements also simplifies the design of the temperature control lines therein.

The temperature control line, through which a liquid or gaseous fluid is conducted at the appropriate temperatures, serves to control the temperature of the frame element. The temperature control line preferably extends over as large an area of the frame element as possible and is dimensioned to allow the fluid to flow through sufficiently to quickly temperature control the frame element. In principle, several separate temperature control lines can be formed in the frame element. However, only one temperature control line is preferably formed in the frame element, so that this can be produced easily.

The tempering line is preferably arranged in such a way that it runs in an area in the vicinity of the flange of the frame element, so that the flange can be effectively tempered.

It is also preferred that the temperature control line is arranged in such a way that it extends along the largest possible area of the flange, so that the temperature of the flange can be controlled uniformly.

The receiving element and the frame element of the tool half can, for example, be held together on a common base plate.

The shaped component is preferably a so-called slosh pad, which is used in liquid containers, in particular in vehicles, in order to reduce sloshing noises of a liquid located therein.

The mat-shaped blank is preferably made from PE-HD threads (PE: polyethylene), the threads more preferably being present in the mat-shaped blank as a knitted fabric, warp-knitted fabric or else in some other way. The threads are preferably connected to one another.

The receiving element is designed with a cavity in which the mat-shaped blank is partially received during production for shaping the body of the molded component.

During production, the mat-shaped blank extends over the receiving element at least into the area of the frame element, so that the mat-shaped blank can be formed into the collar of the molded component in this area.

The receiving element and the frame element can be thermally decoupled, for example by forming a gap between the receiving element and the frame element. The gap may be at least partially filled with a thermal decoupling material, for example in the form of a refractory tape.

The two tempering medium connections define a beginning and an end of the tempering line through which the fluid flows. In addition, line sections can be formed in the frame element through which the fluid does not flow during operation.

The frame element is preferably made of a material with good thermal conductivity in order to enable a rapid change in temperature in the area of the flange, for example aluminium.

The mold is embodied as a press, for example, in order to move the two mold halves between the open state and the closed state. The tool halves are positioned in such a way that the openings of the corresponding receiving elements are opposite one another and the mat-shaped blank is partially enclosed by the two receiving elements in the closed state for shaping the body. Correspondingly, the flanges of the corresponding frame elements are positioned in such a way that they face one another and the mat-shaped blank is pressed between them in the closed state to form the collar of the molded component. Corresponding receiving elements of the two tool halves for the production of the molded component can in principle be of any shape, so that the molded component produced can in principle also be shaped in any way by the two receiving elements. The production of symmetrical molded components is widespread, so that the corresponding receiving elements also have symmetrical shapes.

In addition, the frame element is temperature-controlled, i.e. temperature-controlled fluid is introduced into the temperature-control line, first to heat the frame element and then to cool the frame element. For this purpose, the molding tool comprises a fluid circuit, and the frame element is connected to the fluid circuit via the temperature control medium connections.

After production, the molded component produced can be removed from the mold in the open state before a new production cycle begins with a new mat-shaped blank.

• - weist das Rahmenelement eine Mehrzahl miteinander kommunizierende Bohrungen auf, die gemeinsam die Temperierungsleitung zwischen den Temperierungsmittelanschlüssen ausbilden, wobei die Bohrungen an einer Außenseite des Rahmenelements verschlossen sind.

Die Bohrungen können in dem Rahmenelement an gewünschten stellen ausgebildet werden und gemeinsam die Temperierungsleitung bilden. Die Bohrungen sind als solche jeweils gerade und in dem Rahmenelement miteinander verbunden, um eine Zirkulation des Temperierungsmittel zu ermöglichen. Die Bohrungen können einfach bereitgestellt werden. Die Bohrungen der Temperierungsleitung sind in geeigneter Weise mit den Temperierungsmittelanschlüssen verbunden. Die Temperierungsmittelanschlüsse können beispielsweise an Öffnungen der Bohrungen angeordnet sein, so dass kein zusätzlicher Anschluss erforderlich ist. Außerdem ist es auf diese Weise unmittelbar möglich, die Temperierungsleitung mit den Temperierungsmittelanschlüssen zumindest teilweise zu verschließen. Undichtigkeiten der Temperierungsleitung werden durch die Bohrungen in dem Rahmenelement sicher vermieden.In an advantageous embodiment of the invention

• - The frame element has a plurality of communicating bores which together form the temperature control line between the tempering medium connections, the bores being closed on an outside of the frame element.

The bores can be formed at desired points in the frame element and together form the temperature control line. As such, the bores are each straight and connected to one another in the frame element in order to enable circulation of the temperature control medium. The holes can be easily provided. The bores in the temperature control line are connected in a suitable manner to the temperature control medium connections. The tempering medium connections can be arranged, for example, at openings in the bores, so that no additional connection is required. In addition, it is directly possible in this way to at least partially close the temperature control line with the temperature control medium connections. Leaks in the temperature control line are reliably prevented by the bores in the frame element.

• - sind die Bohrungen zumindest teilweise als Sackbohrungen ausgeführt.

Die Sackbohrungen sind einseitig verschlossen, so dass auf der verschlossenen Seite kein Austritt von Fluid aus der Temperierungsleitung erfolgen kann. Die Herstellung der Werkzeughälfte und entsprechend des Formwerkzeugs kann somit einfach durchgeführt werden. Auch ist die Arbeitszeit zur Herstellung der Sackbohrung geringer als bei einer Durchgangsbohrung, da das Loch eine geringere Länge aufweist. Typischerweise ergeben sich auch weniger Leitungsbereiche, in denen das Temperierungsmittel nicht zirkuliert, sondern steht, insbesondere wenn Sackbohrungen an ihren Sackenden miteinander kommunizieren.In an advantageous embodiment of the invention

• - The holes are at least partially designed as blind holes.

The blind holes are closed on one side so that no fluid can escape from the temperature control line on the closed side. The production of the tool half and accordingly the mold can thus be carried out easily. Also, the working time for making the blind hole is less than for a through hole because the hole has a shorter length. There are also typically fewer line areas in which the temperature control medium does not circulate but stands still, particularly when blind bores communicate with one another at their blind ends.

• - weist das Rahmenelement Verschlusselemente, insbesondere als Stopfen, auf, welche die Bohrungen an der Außenseite des Rahmenelements verschließen.

Allgemein können mit den Stopfen Öffnungen der Bohrungen, die keine Funktion aufweisen, einfach verschlossen werden, um die Temperierungsleitung zu bilden. Auch kann die Temperierungsleitung flexibel und mit einer beliebigen Anzahl von Bohrungen realisiert werden, indem beispielsweise Bohrungen, die einen Mittelabschnitt der Temperierungsleitung bilden, an ihren offenen Enden mit den Stopfen verschlossen werden. Die Stopfen können in Öffnungen der Bohrungen eingesteckt werden, was eine einfache Möglichkeit des Verschlusses bildet. Die Stopfen können beispielsweise aus einen elastisch und/oder plastisch verformbaren Kunststoffmaterial hergestellt sein, so dass der Verschluss der Bohrungen unmittelbar durch das Einsetzen der Stopfen erfolgt. In an advantageous embodiment of the invention

• - The frame element has closure elements, in particular as plugs, which close the bores on the outside of the frame element.

In general, openings in the bores that have no function can simply be closed with the plugs in order to form the temperature control line. The temperature control line can also be implemented flexibly and with any number of bores, for example bores that form a middle section of the temperature control line being closed at their open ends with the plugs. The plugs can be inserted into the openings of the bores, which is an easy way of closing. The plugs can be made, for example, from an elastically and/or plastically deformable plastic material, so that the bores are closed directly by inserting the plugs.

A more complex closure, for example by sintering, is therefore not required.

• - ist der Flansch des Rahmenelements als umlaufende, ebene Fläche ausgeführt, oder
• - der Flansch des Rahmenelements weist einen umlaufenden inneren Bereich und einen umlaufenden äußeren Bereich auf, wobei der äußere Bereich gegenüber dem inneren Bereich vorsteht, wobei insbesondere zwischen dem inneren Bereich und dem äußeren Bereich ein vorzugsweise kontinuierlicher Übergangsbereich ausgebildet ist.

Der Flansch kann insgesamt als ebene Fläche ausgeführt sein zum Verpressen des mattenförmigen Rohlings zur Ausformung des Kragens. Alternativ umfasst der Flansch zwei umlaufende Bereiche, wodurch der Kragen der Formbauteils mit zwei unterschiedlich stark komprimierten Abschnitten hergestellt werden kann, wenn der Flansch gegen einen ebenen Flansch einer zweiten Werkzeughälfte gepresst wird. Alternativ kann der Flansch der zweiten Werkzeughälfte ebenfalls eine entsprechende Form mit zwei umlaufenden Bereichen aufweisen, wobei der äußere Bereich gegenüber dem inneren Bereich vorsteht. Allgemein kann durch die Verwendung des Flanschs mit den zwei umlaufenden Bereichen der Kragen der Formbauteils mit zwei unterschiedlich stark komprimierten Abschnitten hergestellt werden. Ein so hergestellter Kragen ermöglicht insbesondere nach der Herstellung des Formbauteils ein einfaches Herausnehmen des Formbauteils aus dem verbleibenden Rohling. Der innere Bereich des Flanschs bewirkt eine weniger starke Kompression des mattenförmigen Rohlings als der äußere Bereich, so dass beispielsweise im Übergang von dem Körper zu dem Kragen die Gefahr des Bruchs verringert wird, beispielsweise die Gefahr des Bruchs der Kunststofffäden des Rohlings. Außerseitig erfolgt durch den äußeren Bereich des Flanschs eine stärkere Kompression des mattenförmigen Rohlings, so dass beispielsweise eine Trennstelle zwischen dem Formbauteil und dem verbleibenden mattenförmigen Rohling definiert wird. Dadurch kann das fertige Formbauteil nach der Herstellung einfach aus dem Formwerkzeug und aus dem umgebenden Rest des mattenförmigen Rohlings entnommen werden. Darüber hinaus ist es möglich, durch den äußeren Bereich das Material des mattenförmigen Rohlings so weit zu verdrängen, dass das Formbauteil bereits von dem verbleibenden Teil des mattenförmigen Rohlings bei der Herstellung automatisch von dem umgebenden Rest des mattenförmigen Rohlings getrennt wird.In an advantageous embodiment of the invention

• - the flange of the frame element is designed as a circumferential, flat surface, or
• - The flange of the frame element has a peripheral inner area and a peripheral outer area, the outer area protruding in relation to the inner area, in particular between the inner ren area and the outer area, a preferably continuous transition area is formed.

The flange can be designed overall as a flat surface for pressing the mat-shaped blank to form the collar. Alternatively, the flange comprises two peripheral areas, whereby the collar of the molded component can be produced with two differently compressed sections when the flange is pressed against a flat flange of a second tool half. Alternatively, the flange of the second tool half can also have a corresponding shape with two peripheral areas, the outer area protruding in relation to the inner area. In general, by using the flange with the two circumferential areas, the collar of the molded component can be produced with two sections that are compressed to different extents. A collar produced in this way enables the molded component to be easily removed from the remaining blank, in particular after the molded component has been produced. The inner area of the flange causes a less strong compression of the mat-shaped blank than the outer area, so that for example in the transition from the body to the collar the risk of breakage is reduced, for example the risk of breaking the plastic threads of the blank. On the outside, the mat-shaped blank is more strongly compressed by the outer area of the flange, so that, for example, a separation point is defined between the molded component and the remaining mat-shaped blank. As a result, the finished molded component can be easily removed from the mold and from the surrounding remainder of the mat-shaped blank after production. In addition, it is possible to displace the material of the mat-shaped blank through the outer area to such an extent that the molded component is already automatically separated from the remaining part of the mat-shaped blank during production from the surrounding remainder of the mat-shaped blank.

• - weist das Aufnahmeelement eine Innenform auf, die sich von einem Rand ihrer Öffnung erweitert, vorzugsweise mit einem kontinuierlichen Verlauf der Innenform.

Die Innenform nimmt bei der Herstellung des Formbauteils einen Teil des mattenförmigen Rohlings auf, aus dem der Körper geformt wird. Die Innenform definiert also eine Form zur Formgebung des Körpers des Formbauteils. Dabei muss die Form des Körpers des fertigen Formbauteils nicht der Innenform entsprechen, sondern die Innenform dient lediglich der Formgebung des Körpers. Der kontinuierliche Verlauf der Innenform ist vorteilhaft, um den Körper des Formbauteils mit einer festen Oberfläche herzustellen und Risse darin zu vermeiden. Außerdem wird eine Gefahr von Rissen im Übergang zu dem Kragen reduziert. Die Öffnung der Innenform definiert einen Rand der Innenform, der vorzugsweise eine Begrenzung für den Körper des herzustellenden Formbauteils darstellt. Von dem Rand erweitert sich die Innenform zur Aufnahme des mattenförmigen Rohlings. Die Innenform bildet somit eine Kavität aus zur Aufnahme des mattenförmigen Rohlings. Insbesondere im Bereich des Rands der Öffnung weist die Innenform einen vorzugsweise kontinuierlichen Verlauf auf, um das Formbauteil mit einem weichen Übergang zwischen Körper und Kragen herzustellen und ein Aufreißen des Formbauteils zu verhindern.In an advantageous embodiment of the invention

• the female element has an internal shape that widens from an edge of its opening, preferably with a continuous progression of the internal shape.

During the manufacture of the molded component, the inner mold accommodates part of the mat-shaped blank from which the body is formed. The inner shape thus defines a shape for shaping the body of the molded component. In this case, the shape of the body of the finished molded component does not have to correspond to the inner shape, but the inner shape is only used to shape the body. The continuity of the inner mold is advantageous in order to produce the body of the molded component with a solid surface and to avoid cracks in it. In addition, the risk of tears in the transition to the collar is reduced. The opening of the inner mold defines an edge of the inner mold which preferably constitutes a boundary for the body of the molded component to be produced. The inner shape expands from the edge to accommodate the mat-shaped blank. The inner shape thus forms a cavity for receiving the mat-shaped blank. In particular in the area of the edge of the opening, the inner shape has a preferably continuous course in order to produce the molded component with a smooth transition between body and collar and to prevent the molded component from tearing open.

• - ist das Aufnahmeelement gegenüber dem Flansch des Rahmenelements zurückgesetzt.

Es ergibt sich also innenseitig von dem Flansch eine zumindest kleine Stufe zwischen dem Aufnahmeelement und dem Flansch des Rahmenelements. Dadurch wird sichergestellt, dass der Kragen in gewünschter Weise zwischen den Flanschen gegenüberliegender Rahmenelemente in dem Formwerkzeug hergestellt werden kann. Auch wird ein sicherer Übergang von dem Körper zu dem Kragen ermöglicht und ein Aufreißen des Formbauteils im Übergang wird verhindert.In an advantageous embodiment of the invention

• - the receiving element is set back with respect to the flange of the frame element.

There is therefore an at least small step between the receiving element and the flange of the frame element on the inside of the flange. This ensures that the collar can be formed in the desired manner between the flanges of opposing frame members in the mold. A secure transition from the body to the collar is also made possible and the molded component is prevented from tearing open in the transition.

• - weist die Werkzeughälfte eine Mehrzahl Aufnahmeelemente und Rahmenelemente auf, wobei jedes Aufnahmeelement an seiner Öffnung von einem Rahmenelement umgeben ist.

Die Mehrzahl Aufnahmeelemente und Rahmenelemente sind jeweils wie oben angegeben ausgeführt. Die Mehrzahl Aufnahmeelemente und Rahmenelemente ermöglicht eine gleichzeitige Herstellung von mehreren Formbauteilen, so dass beispielsweise der mattenförmige Rohling effizient genutzt werden und ein Durchsatz bei der Fertigung gesteigert werden können. Dabei können prinzipiell beliebig geformte Formbauteile gleichzeitig hergestellt werden. Die unabhängige Bereitstellung der einzelnen Aufnahmeelemente und Rahmenelemente für die Werkzeughälfte ermöglicht dabei eine große Flexibilität in der Produktion. Die Werkzeughälfte muss nicht als Ganzes beispielsweise einteilig hergestellt werden, sondern kann basierend auf den Aufnahmeelementen und Rahmenelementen flexibel hergestellt werden. Das Formwerkzeug kann durch einen Austausch einzelner Aufnahmeelemente mit den dazugehörigen Rahmenelementen schnell umgerüstet werden zur Herstellung unterschiedlich geformter Formbauteile.In an advantageous embodiment of the invention

• - the tool half has a plurality of receiving elements and frame elements, each receiving element being surrounded at its opening by a frame element.

The plurality of receiving elements and frame elements are each configured as indicated above. The plurality of receiving elements and frame elements enables a simultaneous production of several molded components, so that, for example, the mat-shaped blank can be used efficiently and throughput in production can be increased. In principle, molded components of any shape can be produced at the same time. The independent provision of the individual mounting elements and frame elements for the tool half enables great flexibility in production. The tool half does not have to be manufactured as a whole, for example in one piece, but can be manufactured flexibly based on the receiving elements and frame elements. By exchanging individual receiving elements with the associated frame elements, the mold can be quickly converted to produce differently shaped molded components.

• - ist bei einer der Werkzeughälften der Flansch des Rahmenelements als ebene Fläche ausgeführt, und
• - bei der anderen Werkzeughälfte weist der Flansch des Rahmenelements einen umlaufenden inneren Bereich und einen umlaufenden äußeren Bereich auf, wobei der äußere Bereich gegenüber dem inneren Bereich vorsteht.

Diese Kombination der unterschiedlichen Flansche ermöglicht eine effiziente Herstellung der Formbauteile mit dem Kragen. Durch die Verwendung des Flanschs mit den zwei umlaufenden Bereichen kann beispielsweise der Kragen der Formbauteils mit zwei unterschiedlich stark komprimierten Abschnitten hergestellt werden. Ein so hergestellter Kragen verringert die Gefahr des Bruchs und ermöglicht nach der Herstellung des Formbauteils ein einfaches Herausnehmen des Formbauteils aus dem verbleibenden Rohling. Außerseitig erfolgt durch den äußeren Bereich des Flanschs eine stärkere Kompression des mattenförmigen Rohlings, so dass beispielsweise eine Trennstelle definiert wird zwischen dem Formbauteil und dem verbleibenden mattenförmigen Rohling. Dadurch kann das fertige Formbauteil nach der Herstellung einfach aus dem Formwerkzeug und aus dem umgebenden Rest des mattenförmigen Rohlings entnommen werden. Darüber hinaus ist es möglich, durch den äußeren Bereich das Material des mattenförmigen Rohlings so weit zu verdrängen, dass das Formbauteil bereits von dem verbleibenden Teil des mattenförmigen Rohlings bei der Herstellung automatisch von dem umgebenden Rest des mattenförmigen Rohlings getrennt wird.In an advantageous embodiment of the invention

• - in one of the mold halves, the flange of the frame element is designed as a flat surface, and
• - in the other mold half, the flange of the frame member has an inner peripheral portion and an outer peripheral portion, the outer portion projecting relative to the inner portion.

This combination of the different flanges enables the molded components with the collar to be manufactured efficiently. By using the flange with the two circumferential areas, for example, the collar of the molded component can be produced with two sections that are compressed to different extents. A collar produced in this way reduces the risk of breakage and allows the molded component to be easily removed from the remaining blank after the molded component has been produced. On the outside, the mat-shaped blank is more strongly compressed by the outer area of the flange, so that, for example, a separation point is defined between the molded component and the remaining mat-shaped blank. As a result, the finished molded component can be easily removed from the mold and from the surrounding remainder of the mat-shaped blank after production. In addition, it is possible to displace the material of the mat-shaped blank through the outer area to such an extent that the molded component is already automatically separated from the remaining part of the mat-shaped blank during production from the surrounding remainder of the mat-shaped blank.

Alternatively, the flange of the second tool half can also have a corresponding shape with two peripheral areas, the outer area protruding in relation to the inner area. The advantages in relation to the collar with the differently compressed areas apply accordingly.

• - ist das Rahmenelement auf der dem Aufnahmeelement abgewandten Seite im Bereich neben dem Flansch mit einer Aussparung ausgeführt, die sich von dem Flansch zurück erstreckt, und deren Rückerstreckung insbesondere kleiner ist als eine entsprechende Tiefe des Aufnahmeelements.

Die Aussparung bewirkt eine teilweise Kompression des mattenförmigen Rohlings außerseitig von dem Flansch, so dass der Kragen einfach und kontrolliert davon getrennt werden kann. Auch wird die Entstehung von Rissen in dem Material des mattenförmigen Rohlings verhindert, so dass die Gefahr von Verunreinigungen der herzustellenden Formbauteile reduziert ist.In an advantageous embodiment of the invention

• - the frame element is designed on the side facing away from the receiving element in the region next to the flange with a recess which extends back from the flange, and whose back extension is in particular smaller than a corresponding depth of the receiving element.

The recess causes partial compression of the mat blank outside of the flange so that the collar can be easily and controlled separated therefrom. The formation of cracks in the material of the mat-shaped blank is also prevented, so that the risk of contamination of the molded components to be produced is reduced.

• 1: eine stark vereinfachte schematische Schnittansicht eines Formwerkzeugs zur Herstellung eines Formbauteils aus einem mattenförmigen Rohling aus einem kompressiblem Kunststoffmaterial mit zwei Werkzeughälften gemäß einer ersten, bevorzugten Ausführungsform der Erfindung;
• 2: eine schematische Schnittansicht des mit dem Formwerkzeug aus 1 hergestellten Formbauteils in einem Aufnahmeelement einer der Werkzeughälften des Formwerkzeugs;
• 3: eine vereinfachte, schematische Darstellung einer der Werkzeughälften des Formwerkzeugs aus 1 mit einer darin ausgebildeten Temperierungsleitung, die aus einer Mehrzahl Sackbohrungen gebildet ist;
• 4: eine vereinfachte, schematische Darstellung einer der Werkzeughälften des Formwerkzeugs aus 1 mit zwei identischen Aufnahmeelementen und Rahmenelementen, die an einer Grundplatte gemeinsam gehalten sind; und
• 5: eine vereinfachte, schematische Detailansicht aus 1 im Bereich von Flanschen der Rahmenelemente.

Further advantages, details and features of the invention result from the exemplary embodiments explained below. Show in detail:

• 1 1: a greatly simplified schematic sectional view of a mold for producing a molded component from a mat-shaped blank made of a compressible plastic material with two mold halves according to a first, preferred embodiment of the invention;
• 2 : a schematic sectional view of with the mold 1 manufactured molded component in a receiving element of one of the tool halves of the mold;
• 3 : a simplified, schematic representation of one of the tool halves of the molding tool 1 with a temperature control line formed therein, which is formed from a plurality of blind bores;
• 4 : a simplified, schematic representation of one of the tool halves of the molding tool 1 with two identical receiving elements and frame elements, which are held together on a base plate; and
• 5 : a simplified, schematic detail view 1 in the area of flanges of the frame elements.

In the description that now follows, the same reference symbols denote the same components or the same features, so that a description of a component that was carried out with reference to one figure also applies to the other figures, so that a repeated description is avoided. Furthermore, individual features that have been described in connection with one embodiment can also be used separately in other embodiments.

1 shows part of a mold 1 for producing a molded component 2, which is 2 is shown, from a mat-shaped blank made of a compressible plastic material according to a first preferred embodiment of the invention.

In this exemplary embodiment, the shaped component 2 is what is known as a slosh pad, which is used in liquid containers, in particular in vehicles, in order to reduce sloshing noises from a liquid located therein.

The molding tool 1 comprises two tool halves 3, one of which is shown in an example in 3 is shown.

The two tool halves 3 are in 3 each with a receiving element 4 for shaping the mat-shaped blank into a body 5 of the molded component 2 and a frame element 6, which surrounds the receiving element 4 at its opening 7, forming a peripheral flange 8 for shaping the mat-shaped blank into a collar 9 of the molded component 2, shown. In this exemplary embodiment, the frame element 6 is made of a metal with good thermal conductivity, for example aluminum.

As can be seen, for example, from the illustration in 4 results, in which the tool half 3 is shown with two identical receiving elements 4 and frame elements 6, the receiving elements 4 and frame elements 6 are held together on a base plate 10.

In the case of the mold 1, the receiving elements 4 and frame elements 6 of the two mold halves 3 are arranged in a corresponding manner for the joint shaping of the mold component 2. The mold 1 is designed in the manner of a press, so that the two mold halves 3 can move between an open state and a closed state. the in the 1 and 5 is visible, are movable relative to each other. In the open state the mat-shaped blank is positionable between the two tool halves 3, and in the closed state the mat-shaped blank is partially enclosed by the corresponding receiving elements 4 to form the body 5 of the mold component 2 and partially between the corresponding flanges 8 of the frame elements 8 to the Collar 9 of the molded component can be pressed.

As can be seen from the illustration in 5 results, the respective receiving elements 4 and frame elements 6 are separated by a gap 11 and thereby thermally decoupled.

Furthermore, as in 3 is shown, a temperature control line 12 is formed in each frame element 6 and extends between two temperature control medium connections 13 .

In this exemplary embodiment, the frame element 6 has a plurality of blind bores 14 communicating with one another, which together form the temperature control line 12 between the temperature control medium connections 13 . The blind holes 14 are drilled from the outer sides 15 of the respective frame element 6 in such a way that they communicate with one another and/or with the tempering medium connections 13, as can be seen from FIG 3 results. The blind holes 14 are closed on the outer sides 15 of the frame element 6 with a closure element 16, which is designed as a plug. The closure elements 16 are inserted into the openings of the blind holes 14 on the outer sides 15 of the frame element 6 . In this exemplary embodiment, the closure elements 16 are produced from an elastically and/or plastically deformable plastic material.

How to continue 3 results, the blind bores 14 are formed and arranged in the frame element 6 in such a way that the temperature control line 12 formed therefrom runs in an area in the vicinity of the flange 8 of the frame element 6 and, with the exception of an area between the temperature control medium connections 13, circumferentially around the opening 7 extends and extends almost completely with the flange 8.

The detail in 5 shows the mold 1 in the closed state. It can be seen that the flange 8 of the in 5 right frame element 6 is designed to be flat, while the flange 8 of the in 5 right frame element 6 has a peripheral inner region 17 and a peripheral outer region 18 . The outer area 18 protrudes from the inner area 17 by a distance b. A continuous transition area 19 is formed between the inner area 17 and the outer area 18 .

How to continue 5 results, the two receiving elements 4 are set back relative to the flanges 8 of the associated frame elements 6 . As a result, there is a free space at a distance d between the receiving elements 4 when the mold 1 is in the closed state. The receiving elements 4 are each half the distance d behind the flange 8 of the in 5 right frame element 6 or behind the outer area 18 of the in 5 left frame member 6 reset.

As can be seen from the 1 and 5 results, the frame elements 6 are each designed on their side facing away from the receiving element 4 in the area next to the flange 8 with a recess 20, which extends back from the flange 8, and whose back extension r is smaller than a corresponding depth t of the receiving elements 4.

With regard to the receiving element 4, it should also be noted that this has an internal shape 21 that extends from an edge 22 of its opening 7 with a continuous course of the inner mold 21 expanded.

The production of the molded component 2 with the mold 1 from the mat-shaped blank is described below. In this exemplary embodiment, the mat-shaped blank is made from PE-HD threads, the threads being present as a knitted fabric and being connected to one another.

At the beginning of a cycle, the mold 1 is in the open state. The mat-shaped blank is placed in the mold 1 between the two mold halves 3 so that it extends over the receiving elements 4 and the frame elements 6 .

The two tool halves 3 are then moved towards one another until the mold is in the closed state, which is shown in the 1 and 5 is shown. The tool halves 3 are positioned in such a way that the openings 7 of the corresponding receiving elements 4 are opposite one another and the mat-shaped blank is partially enclosed by the two receiving elements 4 in the closed state for shaping the body 5 of the molded component 2. The flanges 8 of the corresponding frame elements are corresponding 6 are positioned so that they face each other and the mat-shaped blank is pressed between them to form the collar 9 of the molded component 2 in the closed state.

In the closed state, the mat-shaped blank is heated and fused in the area of the collar 9 by the corresponding frame elements 6 . For this purpose, the frame elements 6 are heated via the temperature control lines 12 formed therein, without also heating the receiving elements 4 due to the thermal separation through the gap 11 . For heating, a liquid or gaseous fluid at a high temperature is conducted via the tempering medium connections 13 into and through the tempering line 12 . For this purpose, the mold 1 includes a fluid circuit, not shown in the figures, with fluid lines 23 which are connected to the tempering medium connections 13 of the frame elements 6 . The heating of the frame elements 6 can already be started in the open state of the mold 1, or only afterwards in the closed state.

After forming the molded component 2 with the body 5 and the collar 9, the frame members 6 are cooled to solidify the collar 9. Correspondingly, a liquid or gaseous fluid is again conducted, but this time at a lower temperature, via the tempering medium connections 13 into and through the tempering lines 12 in order to cool the frame elements 6 and the corresponding collar 9 above them.

In the production of the molded component 2, the collar 9 between the two flanges 8 is produced with two differently compressed sections in accordance with the inner region 17 and the outer region 18 of the flange 8 of the 1 and 5 left frame element 6.

The mold 1 is then transferred to the open state in which the molded component 2 produced can be removed therefrom before a new production cycle begins with a new mat-shaped blank.

Reference List

1

molding tool

2

molded part

3

tool half

4

receiving element

5

Body

6

frame element

7

opening

8th

flange

9

collar

10

base plate

11

gap

12

temperature control line

13

Tempering medium connection

14

blind hole

15

outside

16

closure element

17

inner area

18

outer area

19

transition area

20

recess

21

interior shape

22

edge

23

fluid line

b

distance (flanges)

i.e

distance (receiving elements)

right

back extension

t

depth

Claims (12)

Tool half (3) for producing a molded component (2) from a mat-shaped blank made of a compressible plastic material, in particular a blank made of connected plastic threads, preferably made of polyethylene, with - a receiving element (4) for shaping the mat-shaped blank into a body (5) of the mold component (2); and - a frame element (6) which surrounds the receiving element (4) at its opening (7) while forming a peripheral flange (8) for shaping the mat-shaped blank into a collar (9) of the molded component (2); - the receiving element (4), the frame element (6) are held together; the tool half (3) being characterized in that - the receiving element (4) and the frame element (6) are thermally decoupled; and - a temperature control line (12) is formed in the frame element (6) and extends between two temperature control medium connections (13). Tool half (3) after claim 1 , characterized in that - the frame element (6) has a plurality of communicating bores which together form the temperature control line (12) between the temperature control medium connections (13), the bores on an outer side (15) of the frame element (6) being closed. Tool half (3) after claim 2 , characterized in that - the bores are at least partially designed as blind bores (14). Tool half (3) according to one of claims 2 or 3 , characterized in that - the frame element (6) has closure elements (16), in particular as plugs, which close the bores on the outside (15) of the frame element (6). Tool half (3) according to one of the preceding claims, characterized in that - the flange (8) of the frame element (6) is designed as a circumferential, flat surface, or - the flange (8) of the frame element (6) has a circumferential inner area ( 17) and a circumferential outer area (18), the outer area (18) protruding in relation to the inner area (17), with a preferably continuous transition area (19 ) is trained. Tool half (3) according to one of the preceding claims, characterized in that - the receiving element (4) has an inner shape (21) which widens from an edge (22) of its opening (7), preferably with a continuous progression of the inner shape ( 21) . Tool half (3) according to one of the preceding claims, characterized in that - the receiving element (4) is set back in relation to the flange (8) of the frame element (6). Tool half (3) according to one of the preceding claims, characterized in that - the tool half (3) has a plurality of receiving elements (4) and frame elements (6), each receiving element (4) being supported at its opening (7) by a frame element (6 ) is surrounded. Mold (1) for producing a molded component (2) from a mat-shaped blank made of a compressible plastic material, in particular a blank made of connected plastic threads, preferably made of polyethylene - Two tool halves (3) according to any one of the preceding claims, which have corresponding receiving elements (4) and corresponding frame elements (6) for the joint shaping of the mold component (2); whereby - the two mold halves (3) are movable between an open condition and a closed condition; - In the open state, the mat-shaped blank can be positioned between the two tool halves (3); - in the closed state the mat-shaped blank is partially enclosed by the corresponding receiving elements (4) to form a body (5) of the molded component (2) and partially between the corresponding flanges (8) of the frame elements (6) to form a collar (9) of the molded component (9) can be pressed. Mold (1) after claim 9 , characterized in that - in one of the tool halves (3) the flange (8) of the frame element (6) is designed as a flat surface, and - in the other tool half (3) the flange (8) of the frame element (6) has a circumferential inner region (17) and a peripheral outer region (18), the outer region (18) protruding relative to the inner region (17). Mold (1) according to one of claims 9 or 10 , characterized in that - the frame element (6) is designed on the side facing away from the receiving element (4) in the area next to the flange (8) with a recess (20) which extends back from the flange (8), and its rearward extension (r) in particular is smaller than a corresponding depth (t) of the receiving element (4). Molded component (2) made from a mat-shaped blank made of a compressible plastic material, in particular a mat-shaped blank made from connected plastic threads, preferably made of polyethylene, the molded component (2) being characterized in that it is formed with the mold (1) according to one of the preceding claims 9 until 11 is made.

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