EP4054828A1 - Method for producing a case component and case having at least one component produced in this way - Google Patents
Method for producing a case component and case having at least one component produced in this wayInfo
- Publication number
- EP4054828A1 EP4054828A1 EP20800142.0A EP20800142A EP4054828A1 EP 4054828 A1 EP4054828 A1 EP 4054828A1 EP 20800142 A EP20800142 A EP 20800142A EP 4054828 A1 EP4054828 A1 EP 4054828A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- plastic composite
- composite plate
- pressing
- case
- mold
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 22
- 239000002131 composite material Substances 0.000 claims abstract description 177
- 239000004033 plastic Substances 0.000 claims abstract description 165
- 229920003023 plastic Polymers 0.000 claims abstract description 165
- 238000003825 pressing Methods 0.000 claims abstract description 105
- 239000000463 material Substances 0.000 claims abstract description 82
- 238000000034 method Methods 0.000 claims abstract description 46
- 238000010438 heat treatment Methods 0.000 claims abstract description 35
- 238000001816 cooling Methods 0.000 claims abstract description 10
- 239000000835 fiber Substances 0.000 claims description 38
- 229920001296 polysiloxane Polymers 0.000 claims description 16
- 239000012815 thermoplastic material Substances 0.000 claims description 14
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 13
- 239000004917 carbon fiber Substances 0.000 claims description 13
- 239000011159 matrix material Substances 0.000 claims description 13
- 229920006231 aramid fiber Polymers 0.000 claims description 12
- 239000004760 aramid Substances 0.000 claims description 11
- 239000003365 glass fiber Substances 0.000 claims description 8
- 238000007711 solidification Methods 0.000 claims description 6
- 230000008023 solidification Effects 0.000 claims description 6
- 230000005855 radiation Effects 0.000 claims description 5
- 230000003750 conditioning effect Effects 0.000 claims 1
- 235000019589 hardness Nutrition 0.000 abstract 2
- 230000006835 compression Effects 0.000 description 32
- 238000007906 compression Methods 0.000 description 32
- 229920001187 thermosetting polymer Polymers 0.000 description 12
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 7
- 229910052799 carbon Inorganic materials 0.000 description 7
- 229920001169 thermoplastic Polymers 0.000 description 7
- 238000013461 design Methods 0.000 description 6
- 239000004416 thermosoftening plastic Substances 0.000 description 6
- 229910000831 Steel Inorganic materials 0.000 description 4
- 230000002349 favourable effect Effects 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 239000004744 fabric Substances 0.000 description 3
- 239000002657 fibrous material Substances 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- -1 polypropylene Polymers 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 239000004952 Polyamide Substances 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 229920000515 polycarbonate Polymers 0.000 description 2
- 239000004417 polycarbonate Substances 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 238000009423 ventilation Methods 0.000 description 2
- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 1
- 239000004433 Thermoplastic polyurethane Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000000748 compression moulding Methods 0.000 description 1
- 239000012809 cooling fluid Substances 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000011151 fibre-reinforced plastic Substances 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 239000007779 soft material Substances 0.000 description 1
- 238000003856 thermoforming Methods 0.000 description 1
- 229920006345 thermoplastic polyamide Polymers 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 238000009966 trimming Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
-
- A—HUMAN NECESSITIES
- A45—HAND OR TRAVELLING ARTICLES
- A45C—PURSES; LUGGAGE; HAND CARRIED BAGS
- A45C5/00—Rigid or semi-rigid luggage
- A45C5/02—Materials therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/261—Handling means, e.g. transfer means, feeding means
- B29C51/262—Clamping means for the sheets, e.g. clamping frames
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/56—Tensioning reinforcements before or during shaping
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
- B29K2023/10—Polymers of propylene
- B29K2023/12—PP, i.e. polypropylene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/12—Thermoplastic materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2277/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as reinforcement
- B29K2277/10—Aromatic polyamides [Polyaramides] or derivatives thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2307/00—Use of elements other than metals as reinforcement
- B29K2307/04—Carbon
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2905/00—Use of metals, their alloys or their compounds, as mould material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2905/00—Use of metals, their alloys or their compounds, as mould material
- B29K2905/02—Aluminium
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0037—Other properties
- B29K2995/007—Hardness
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/7418—Suitcases
Definitions
- the invention relates to a method for producing a case component, which is curved at least in sections several times, from a plastic composite panel by pressing.
- the invention further relates to a suitcase with at least one half-shell-shaped component which is produced using such a method.
- Case shells typically have a relatively high depth (e.g. 10-15 cm) compared to their width (30-50 cm) and height (40-70 cm).
- the side walls In order to maximize the interior space of the case, it is advisable to make the side walls normal to the top walls or the front walls, as is the case with a cuboid.
- the walls themselves are typically essentially flat in the case of suitcases. In practice, these flat areas can have grooves, design elements, reinforcements and the like, whereby it is only essential for the present invention that the case has areas that are not or less strongly curved than other areas, such as edges or corner points ( "Case corners").
- the side surfaces of the case shells are referred to as "essentially flat areas”.
- case shells This includes all designs of case shells, including shells with grooves or other (curved) shapes.
- the edges of the case shell are usually simply curved.
- the material In the areas where the side walls, top walls and front walls meet, the material must be curved several times, ie along at least two axes ("case corners"). For this, the material must be able to be stretched and compressed If the essentially flat areas have ornamental shapes, then these shapes are often curved several times, but mostly less than on the corners of the case.
- Fibers especially carbon fibers or aramid fibers, used to reinforce plastics can hardly be stretched or compressed at all.
- the fibers In order to keep the design To enable fiber-reinforced materials, the fibers must be able to be moved relative to one another. The longer the fibers, the more difficult it is to move the fibers and the more difficult it is to shape.
- High-quality, ie particularly strong and visually appealing carbon components usually have a fiber fabric that extends with "endless" long fibers over the entire component dimensions. This is the only way to ensure an appealing "carbon look”.
- the US 2010/0181018 Al relates to the production of composite parts in compression molds at elevated temperature.
- typically several, initially soft layers of woven or unidirectional fibers, which are typically already soaked in a matrix made of thermosetting plastic (short: "prepregs") are delivered onto a surface of a rigid, heatable mold
- prepregs thermosetting plastic
- the composite laminate is covered with a ventilation cloth through which, supported by the application of a negative pressure, excess gas and thermosetting resin can escape during molding.
- a base mold made of thermally insulating material is countered with a silicone layer facing the composite laminate the composite laminate is pressed.
- thermosetting Materials The distribution of the thickness of this silicone layer is calculated beforehand in order to achieve a uniform pressure distribution on the composite laminate.
- the molds are then closed and the air is sucked out using vacuum devices.
- the molds are also heated, so that the previously soft, deformable composite laminate with a thermoset matrix hardens and thus becomes stiff and strong.
- the curing of thermosetting Materials usually takes several hours.
- the silicone side of the mold cannot have a varying thickness or varying silicone hardness, since the entire side of the mold is made from one block Silicone is a very good thermal insulator, this side of the mold can are not heated or cooled, which in turn creates major disadvantages in the manufacturing process.
- the authors state that this method is rarely used successfully in practice, especially with more complex or multi-curved surfaces.
- a method of pressing using many small silicone cuboids or silicone balls is suggested. This method avoids long series of tests, but a high-quality and smooth inside of the component surface cannot be achieved. This method is therefore not suitable for case shells, which must be of high quality both inside and outside.
- the resulting "creases" in the interior of the components have disadvantages with regard to the strength of the components.
- the disadvantages of the lack of temperature control are also given with this alternative method.
- EP 3225 735 A1 describes plastic composite panels made of fiber-reinforced plastic materials and molded parts made from them, without going into detail on the manufacturing process. Fibers with a maximum length of 15 mm are used, which can be easily deformed as a result, but do not have a high-quality look.
- the mold consists of two simple halves made of metal. With fiber lengths Over 50 mm or even continuous fibers that extend over the entire component, however, special processes are necessary.
- EP 0 040 967 A2 shows fiber-reinforced thermoplastic plastic composite sheets which can only be heated in certain areas for deformation. These other areas remain cold and undeformed. Case shells with multiple curved zones, especially when it comes to shells with endless fibers, would have to be heated everywhere for processing in order to enable deformability.
- thermoset carbon components are therefore time-consuming and costly. This results in components with a thermosetting matrix, which are very stiff, but also relatively brittle.
- Known methods for thermoplasti cal components offer too little control over the manufacturing process and inadequate surface quality. Known methods are therefore not suitable, in particular for multiply curved case corners or shell components in complex shapes.
- the object of the invention is to create a method of the type mentioned above, with which the case component can be produced quickly and as automatically as possible, with a low weight and high strength.
- the manufacture of suitcase components with continuous fibers should also enable who the. Disadvantages of known methods should be prevented or at least reduced. It is also an object of the invention to create a case which has at least one half-shell-shaped component produced with such a method.
- a plastic composite sheet is understood to mean a sheet with fiber material and a binding agent which, depending on the temperature acting on it, softens and can be hardened.
- the fibers are fixed in the Bindemit tel and give the plastic composite panel appropriate strength and stability.
- the plastic composite panel is Herge before the method according to the invention is carried out and can thus have favorable properties for use in the process.
- the plastic composite panel can be provided with a sufficiently small number of air inclusions, so that when the plastic composite panel is reshaped, it is possible to dispense with a ventilation cloth and the application of a negative pressure.
- the plastic composite plate can be angular, for example rectangular or square, or in special two-dimensional precut shapes.
- the plastic composite plate used in the method according to the invention has at least one fiber mat with carbon fibers and / or aramid fibers and / or glass fibers.
- the fiber mat is bound in a matrix made of thermoplastic material, which is solid at room temperature and becomes soft when heated.
- the plastic composite plate is provided in an essentially solid, ie inflexible, state prior to heating and is therefore easy to transport and handle. In this state, the plastic composite plate is not flexible enough to be placed on a pressing surface of the pressing device.
- ther moplastic polyurethane, polypropylene or polyamide or polycarbonate is used as the thermoplastic material.
- the plastic composite plate has carbon fibers and aramid fibers in thermoplastic polyamide.
- the thermoplastic material polyurethane, polyamide, polypropylene, polycarbonate and the like
- the plastic composite sheet is heated to a softening temperature with a heating device.
- the softening temperature is thus a temperature at which the plastic composite plate is soft enough to be deformed by pressing in the pressing device.
- the softening temperature for this lies in a temperature range in which the plastic composite sheet, in particular the thermoplastic material, loses its rigid property and achieves a suitable higher flexibility.
- a favorable value of the softening temperature thus depends on several parameters, such as the material composition, the desired deformation and the thickness of the plastic composite panel and can be determined by a person skilled in the art without problems.
- the compression molds have mutually facing, at least partially curved pressing surfaces which, when the Kunststoffver composite plate is pressed, bear against opposing surfaces of the Kunststoffver composite plate.
- the compression molds or their compression surfaces thus give the plastic composite plate received and pressed in between the desired shape of the component.
- the pressure with which the first and the second compression mold press against one another and thus on the plastic composite plate can be determined by a person skilled in the art without problems.
- the first and second compression molds are provided with materials of different hardness.
- the first and / or the second compression mold preferably have two materials of different hardness.
- the comparatively softer material is provided in at least one partial area of the pressing surface of the first and / or second press mold. If the first or second compression mold have more than two materials of different hardness, the softer material is understood to be the comparatively softest of the materials, which is why only a softer material is referred to in the further course of the description.
- the softer material of the first and / or second compression mold presses against the likewise soft plastic composite plate.
- the hardness of the softer material is chosen so that the plastic composite sheet that is being pressed can deform the softer material. This is a significant difference to essentially rigid dies and press surfaces made of steel or aluminum.
- the particular advantage of the mold (s) with softer material is that it makes the comparatively softer material of the Compression molding of the plastic composite plate being pressed provides a tolerance range in which the plastic composite plate can expand or shift or deform more freely, and thus essentially assume a shape that does not correspond exactly to that of the compression mold or more gently into the desired shape slides.
- the plastic composite panel is allowed, within certain tolerances, to find itself, so to speak, a shape appropriate to the material and to find itself in this shape more gently. Accordingly, an evenly distributed pressure does not necessarily act on the plastic composite panel that is being pressed. Rather, the pressure exerted on the plastic composite plate by the softer material of the press mold is less than the pressure exerted on the plastic composite plate by any harder material of the press mold.
- the pressure on different areas of the plastic composite panel can be different and can be adjusted optimally in each case. In this way, damage, e.g. creases or cracks, to the plastic composite plate in the at least part of the pressing surface in which the softer material is provided, is avoided, because the material can use the tolerance range allowed by the soft material in order to to find a similar but not necessarily exactly the same shape.
- first and second compression molds have materials of different hardness
- first and second compression molds have materials of different hardness
- both the first compression mold and the second compression mold have two materials of different hardness or only the first or the second die Ma have materials of different hardness.
- the plastic composite plate still held in the pressing device and already pressed is cooled to a solidification temperature which is lower than the softening temperature.
- the pressing pressure can be adjusted as long as it is ensured that the shape of the plastic composite plate produced by the pressing, i.e. the shape of the case component, is maintained during cooling.
- the solidification temperature is in a temperature range in which the plastic composite panel again assumes its solid property, but in particular high rigidity and high elongation at break, that is to say high dimensional stability.
- a favorable value for the solidification temperature depends on several parameters, such as the material composition and the thickness of the plastic composite panel and can be determined by a specialist without problems.
- the cooling process can last a few minutes, in particular less than 5 minutes, preferably less than 3 minutes.
- the mold In order to obtain the most appealing surface of the case component, it is beneficial to regulate the temperature of the mold. So at the beginning it makes sense to keep the temperature of the mold rather high so that the thermoplastic material on the surface of the mold is kept nice and soft and, so to speak, melts onto the surface. Thus, the mold is conveniently heated at the start of the cycle and then cooled. Heating and cooling can be done with water, steam, oil, electrical and so on, these are well-known methods.
- the pressing device is opened and the solidified, at least partially curved plastic composite plate is removed from the pressing device as a case component.
- the cycle time is compared to known methods for producing a component of several hours reduced to typically a few minutes.
- the case component is given a shape similar to the press mold, but the material is deliberately allowed a tolerance in selectable component sections, which is controlled by the thickness and hardness of the soft pressing area. It is only through this tolerance that certain more complex shapes, such as, for example, multi-curved surfaces, are possible.
- multi-curved surfaces we mean surfaces that are not only curved along one axis (for example a pipe), but at the same time also along at least one second axis (for example the rounded corner of a cuboid or "suitcase corners") the multi-curved surfaces are in narrower radii, the tolerance in the press molds helps in the flawless realization of the component.
- thermoplastics Through the use of thermoplastics, a case component is created from a prefabricated plastic composite panel by forming, which has high strength and high elongation at break with low weight at the same time. This is also ensured by the suitable structure of the Kunststoffver composite plate.
- Thermoplastics are typically lighter (density 1-1.2 grams per cubic centimeter) than thermoset (density 1.2-1.5 grams per cubic centimeter) plastics.
- thermoplastics have a higher elongation at break of, for example, more than 20%, while thermosets often only reach 3%. This means that the composite sheet with thermoplastics only breaks when it is deformed significantly more.
- the impact strength of thermoplastics is also superior to that of thermosets.
- the fibers in the composite panel in turn increase de ren stiffness and toughness.
- Aramid fibers are typically very tough, while carbon fibers are rather stiff.
- the structure of the composite panel can be optimized with a suitable combination of different types of fibers, different fiber materials and a different number of layers and thicknesses of fibers. Since the plastic composite plate or the case component does not have to be cured or solidified in an oven over a long period of time, the case component can be manufactured particularly quickly. In addition, there is no need for the time-consuming manual insertion of several layers into a press mold, since the plastic composite panel to be received in the press device is already present is delivered ready.
- the first and / or second press mold is formed with the softer material at least in the area of the curvatures of the press surface.
- the pressing surface thus has elevations and / or depressions, which provide the plastic composite plate with differently pronounced tolerance ranges during pressing.
- the softer material of the first and / or second press mold is thicker and / or softer in the area of the curvatures of the press surface than in a comparatively flat area of the press surface. Accordingly, depending on the design and arrangement of the softer material, the pressure on curved areas of the plastic composite plate can be lower than on comparatively flat areas of the plastic composite plate. In this way, the plastic composite panel is given more leeway to deform in the area of the curvatures, i.e. in the area of major deformations, and damage, as often occurs in the case of compression molds that do not provide any leeway, is avoided.
- the plastic composite plate is provided with a thickness of less than 3 mm, preferably less than 1 mm.
- the plastic composite plate is provided with a thickness between 0.5 mm and 1 mm. Due to the small thickness, the plastic composite panel and thus also the construction made from it can have a low weight.
- previously known carbon components of comparable shape with a greater thickness are produced in order to compensate for the disadvantage of the very low elongation at break of thermosetting plastics and to achieve a sufficiently high strength, which, however, increases the weight of the case component unfavorably and thus the advantage the low weight of carbon compared to other materials is at least partially nullified.
- the thickness of the plastic composite panel used in the process according to the invention can be, for example, half or a third due to the higher elongation at break and the higher impact strength or less.
- the plastic composite plate can have a constant thickness before it is received in the pressing device.
- the plastic composite panel has an area ranging from 0.2 m 2 to 10 m 2 .
- the holding device can have several components for gripping and transporting the plastic composite panel.
- the plastic composite plate can preferably be gripped with the holding device, fed to the heating device, held in the heating device during heating and placed in a suitable position in the heated state in the pressing device.
- the holding device can be operated in an automated manner, for example electrically, pneumatically or hydraulically controllable.
- the plastic composite plate is received in at least one robot arm of the holding device.
- the robot arm is preferably designed to move the plastic composite panel in all three spatial dimensions.
- the robot arm can have swivel axes in the three spatial dimensions.
- the robot arm preferably has at least one gripping tool, for example in the form of pliers, for gripping the plastic composite plate.
- the plastic composite plate can be reliably held in the frame.
- the plastic composite plate can be connected at its peripheral edge to first ends of the fixing elements, and second ends of the fixing elements are connected to the frame.
- the frame can partially or completely surround the plastic composite panel. The frame can thus be gripped in order to hold and transport the plastic composite panel.
- the fixing elements are designed to be stretchable or displaceable, preferably only in a few positions, For example, the four corners that hold the plastic composite panel, the position of the plastic composite panel can be changed in the frame during the deformation of the plastic composite panel.
- the material can slide into the mold even more flexibly and the result is improved.
- the fixing elements can be spring elements or the like.
- the heating of the plastic composite plate can take place particularly quickly, in a space-saving and inexpensive manner, if the plastic composite plate is heated by infrared radiation in the heating device.
- the heating device has at least one source for infrared radiation.
- the plastic composite plate is heated to different intensities in the heating device in different partial areas, since there is usually a softening temperature range.
- the plastic composite panel can be heated more strongly in sub-areas to be deformed than in sub-areas that are comparatively less to be deformed.
- the plastic composite plate can be cooled by means of a preferably controllable temperature control device (heating and / or cooling device) of the pressing device.
- the pressing device can have channels for a cooling fluid to pass through.
- pelt elements for cooling the plastic composite plate are conceivable.
- the temperature control device can be controlled electrically.
- the first and / or second mold with a Layer of silicone provided as a softer material Preferably, the first and / or second mold with a Layer of silicone provided as a softer material.
- the thickness and hardness of the layer made of silicone or of the softer material can vary along the pressing surface. In particular, the thickness and the hardness of the layer made of silicone or of the softer material along the pressing surface can be adjusted so that when the plastic composite plate is pressed, differently defined pressure is exerted on defined areas of the plastic composite plate.
- the plastic composite plate is advantageously provided with a sufficiently large tolerance range for the deformation of the plastic composite plate in the area of the corners and / or edges to be manufactured by means of the softer material .
- the object of the invention is also achieved by a case with at least one half-shell-shaped case component, which is manufactured using the method defined above and has a plastic composite panel which has at least one fiber mat with at least one of carbon fibers, aramid fibers or glass fibers, which fiber mat in a matrix made of thermoplastic material is bound, the layer thickness of the half-shell-shaped component being less than 3 mm, preferably we niger than 1 mm.
- the case can in particular have two half-shell-shaped case components produced using the method described, for example a base part and a cover part, which are connected to one another via hinges, zippers and other connecting elements.
- the suitcase produced using the method described above is characterized by high strength and high elongation at break with low weight.
- the half-shell-shaped case component has single or multiple curved, in particular rounded corners and / or edges, in particular free of additional reinforcements or material interruptions.
- the case is therefore also in the range of Curvatures, ie in the area of the singly or multiply curved (rounded) corners and / or edges, stable and made in one piece.
- the method described above is carried out with a device for producing an at least partially curved case component from a plastic composite plate by pressing, which plastic composite plate has at least one fiber mat with at least one of carbon fibers, aramid fibers or glass fibers, which fiber mat in a matrix of thermoplastic material is bound, with a first press mold and a second press mold movable towards and away from it, which press form men have facing press surfaces intended to rest on the plastic composite plate during pressing, with a heating device separate from the press device for Heating of the plastic composite plate is provided, the first and second compression molds have materials of different hardness and the softer material is provided in at least a partial area of the pressing surface of the first and / or second compression mold en is.
- the device for producing the construction part reference is also made to the preceding description of the method.
- the softer material can form curvatures, i.e. elevations and / or depressions, of the pressing surface.
- the softer material can have different thicknesses.
- the softer material in the area of the curvatures of the pressing surface can be thicker or harder and / or softer or thinner than be formed in a comparatively flat area of the pressing surface.
- the first and second press molds advantageously have metal, the pressing surface of one of the first or second press molds then having the softer material.
- the softer material is preferably a layer of silicone.
- the pressing device is designed to bring the first and second press mold closer to one another to less than 3 mm, preferably less than 1 mm.
- a holding device associated with the heating device and the pressing device can be provided for the plate.
- the holding device can have at least one robot arm for receiving the plastic composite panel.
- the holding device can have a frame with fixing elements for receiving the plastic composite panel in the frame.
- the fixing elements can be formed out in a stretchable manner.
- the heating device preferably has an infrared heater.
- the heating device can be designed to heat the plastic composite panel to different degrees in different subregions.
- the pressing device can have a preferably controllable, in particular a special electrically controllable temperature control device (heating and / or cooling device). Both molds of the pressing device are preferably tempered.
- FIG. 1 shows a plastic composite panel with several fiber layers in a matrix of thermoplastic material in a sectional view
- FIG. 2 shows a case component made from the plastic composite plate of FIG. 1 in a sectional view
- FIG. 3 shows the plastic composite plate from FIG. 1 in a heating device
- FIG. 4 shows the plastic composite plate from FIG. 1 in a frame of a holding device in a view from above;
- FIG. 5 shows a press device with a first press mold and a second press mold which can be moved towards and away from it, in an open state, and with softer material on the press surface of the second press mold in a sectional view;
- 6a and 6b show two embodiments of a pressing device from FIG. 5 with the plastic composite plate from FIG. 1 received therein, in a closed state, during pressing;
- FIG. 7 shows successive steps of a method for producing an at least partially curved component from the plastic composite panel of FIG. 1;
- Fig. 8 shows a case in the open state, with two half-shell-shaped case components, which were made to drive with the Ver according to the invention, in a sectional view;
- FIG. 1 shows a plastic composite plate 2 which has at least one fiber mat 5 with at least one of carbon fibers, aramid fibers or glass fibers, which fiber mat 5 is bound in a matrix 6 made of thermoplastic material.
- FIG. 1 shows an exemplary plastic composite panel 2 with a fiber mat 5 composed of three fiber layers 5 a arranged one above the other, an aramid fiber layer 4 being arranged between two carbon fiber layers 3.
- the shape of the Plastic composite panel 2 can in principle be any.
- the plastic composite plate 2 can be angular, in particular rectangular (see FIG. 4) or square, or round.
- the plastic composite panel 2 has a length L, a width B and a height or thickness D.
- an exemplary case component 1 is shown, for example a half-shell of a case that was obtained from the plastic composite panel 2 by means of uniforms.
- Fig. 3 shows schematically a heating of the plastic composite plate 2 with a heating device 7 to a softening temperature.
- the plastic composite plate 2 can be accommodated in the heating device 7.
- the heating device 7 has an infrared heater in order to heat the plastic composite panel 2 by means of infrared radiation R to it.
- the plastic composite plate 2 is advantageously heated on its two opposing main surfaces F (see FIG. 1).
- the plastic composite plate 2 can be received in a holding device 15 before heating and thereby the heating device 7 and a pressing device 8 shown in FIGS. 5 and 6a and 6b are supplied.
- the plastic composite plate 2 can be received in at least one robot arm 26 of the holding device 15.
- the plastic composite plate 2 can additionally or alternatively be received by means of fixing elements 16 in a frame 17 of the device 15 Hal. In the example shown in FIG. 7 it can be seen that the plastic composite plate 2 is held in the frame 17 and that the latter is gripped by a robot arm 26. Alternatively, the robot arm 26 or several robot arms 26 can grip the plastic composite panel 2 directly.
- the fixing elements 16 can be elastic or stretchable, for example in the form of spring elements.
- FIG. 5 shows an exemplary press device 8 with a first press mold 9 and a second press mold 10 that can be moved towards and away from it.
- the direction of movement of the two Molds 9, 10 towards each other and away from each other is through a
- the plastic composite plate 2 heated to the softening temperature is received between the first mold 9 and the second mold 10 of the pressing device 8 and pressed.
- the two compression molds 9, 10 have pressing surfaces 11 facing one another and provided during pressing to rest on the plastic composite plate 2.
- the first and second press molds 9, 10 have materials 12, 13 of different hardness.
- the softer material 12 is provided in at least a partial area 14 of the pressing surface 11 of the first and / or second press mold 9, 10.
- the first press mold 9 has the harder material 13 or is formed therefrom and the second press mold 10 also has the harder material 13 but additionally has the softer material 12 on the pressing surface 11.
- both the first and the second compression mold 9, 10 can have both the harder material 13 and the softer material 12 on the pressing surface 11. It is essential that when the plastic composite plate 2 is pressed, the softer material 12 rests against at least part of it and presses against the plastic composite plate 2. It is also conceivable that the first press mold is made completely from the harder material 13, for example metal, and the second press mold is made completely from softer material 12.
- 6a and 6b show the exemplary pressing device 8 during the pressing of the plastic composite plate 2 received between the first compression mold 9 and the second compression mold 10 in two embodiments.
- the plastic composite plate 2 in compression assumes the shape given by the pressing surfaces 11.
- first compression mold 9 and / or the second compression mold 10 for example one of the compression molds 9, 10, in particular the second compression mold 9, with curvatures 19,
- the press surface 11 of the first press mold 9 is made of the harder material 13 Curvatures 19 in the form of elevations 19a and the pressing surface 11 of the second press mold 10, which pressing surface 11 is formed from the white material 12, has corresponding curvatures 20 in the form of depressions 20a.
- the first compression mold 9 could also have the softer material 12 with elevations 19a or depressions 20a.
- the first press mold 9 and / or the second press mold 10, for example one of the press molds 9, 10, in particular the second press mold 9, can be provided with the softer material 12, which is in the area of the curvatures 19, 20 of the press surface 11 is thicker and / or softer than in a comparatively flat area 21 of the pressing surface 11.
- the thicker and / or softer design of the softer material 12 provides the plastic composite plate 2 in the area of the curvatures 19, 20 of the pressing surface 11 with a greater tolerance range for the deformation than in the comparatively flat area 21 of the pressing surface 11 / or a second compression mold 9, 10 can be provided with a layer 22 made of silicone as the softer material 12.
- a temperature control device 18 of the pressing device 8 can also be seen in order to be able to heat and cool the plastic composite plate 2 by means of the temperature control device 18, which is preferably designed to be controllable.
- both pressing devices 9 and 10 are preferably tempered in order to be able to guarantee the highest possible surface quality.
- the plastic composite plate 2 received and pressed in the pressing device 8 is cooled to at least a solidification temperature which is lower than the softening temperature.
- the pressing device 8 is opened, i.e. the first compression mold 9 and the second compression mold 10 are moved away from each other, and the solidified plastic composite plate 2, which is curved at least in sections, is removed as component 1 from the pressing device 8.
- Figure 6b shows an embodiment of a pressing device 8 for the production of a deeper case shell, wherein the mold 10 is formed by a soft layer 12 and a temperature-controlled core made of hard material.
- the soft layer 12 shows areas of different thicknesses 29 and 30, with the area 30 being approximately twice as thick as the area 29 in this example.
- Fig. 7 successive, separated by arrows Darge presented steps of the method for producing an at least partially curved component 1 from the plastic composite plate 2 can be seen.
- the plastic composite plate 2 that is to say not flexible enough to be placed on a pressing surface 11, is provided, then the plastic composite plate 2 is received in a holding device 15, for example in a frame 17 and a robot arm 26 Holding device 15 recorded plastic composite plate 2 is heated with a heating device 7 in order to be suitably inserted into the mold 9, 10 or placed on the pressing surface 11, then the heated plastic composite plate 2 is received between the molds 9, 10 of the pressing device 8 , whereupon the pressing device 8 is closed and the plastic composite plate 2 is pressed and cooled in the pressing device 8 in order to solidify, and finally the pressing device 8 is opened and the plastic composite plate 2 is removed as component 1 from the pressing device 8.
- FIG. 8 shows an exemplary case 23a with at least one half-shell-shaped case component 24, in particular two half-shell-shaped case components 24, which case component 24 / which case components 24 is / are manufactured using the method described, and a plastic composite panel 2 has / have, which has at least one fiber mat 5 with at least one of carbon fibers, aramid fibers or glass fibers, which fiber mat 5 is bound in a matrix 6 made of thermoplastic material, the layer thickness D of the half-shell-shaped case component 24 / the half-shell-shaped case- Components 24 is less than 3 mm, preferably less than 1 mm.
- the layer thickness D of the half-shell-shaped case component 24 is essentially the thickness D of the plastic composite plate 2.
- the half-shell-shaped case components 24 of the manufactured case 23a for example a bottom part and a lid part of the case 23a are connected to one another by means of a hinge 27, for example.
- the half-shell-shaped case component 24 has multiply curved corners and / or edges 25 and / or single curved corners / edges 28.
- FIG. 9 shows two three-dimensional views of a half-shell-shaped case component 24 which has both single curved sections “case edges” 28 and double or multiple curved sections “case corners” 25.
- the method of forming according to the invention is particularly advantageous for producing the multiply curved sections.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP19207386.4A EP3819104A1 (en) | 2019-11-06 | 2019-11-06 | Method for producing a component and container with at least one such component |
PCT/EP2020/080890 WO2021089586A1 (en) | 2019-11-06 | 2020-11-04 | Method for producing a case component and case having at least one component produced in this way |
Publications (1)
Publication Number | Publication Date |
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EP4054828A1 true EP4054828A1 (en) | 2022-09-14 |
Family
ID=68470340
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP19207386.4A Withdrawn EP3819104A1 (en) | 2019-11-06 | 2019-11-06 | Method for producing a component and container with at least one such component |
EP20800142.0A Pending EP4054828A1 (en) | 2019-11-06 | 2020-11-04 | Method for producing a case component and case having at least one component produced in this way |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP19207386.4A Withdrawn EP3819104A1 (en) | 2019-11-06 | 2019-11-06 | Method for producing a component and container with at least one such component |
Country Status (2)
Country | Link |
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EP (2) | EP3819104A1 (en) |
WO (1) | WO2021089586A1 (en) |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS56164842A (en) * | 1980-05-23 | 1981-12-18 | Toray Industries | Carbon fiber reinforced thermoplastic resin molding |
US8511362B2 (en) | 2009-01-16 | 2013-08-20 | Edwin H. Kintz | Consolidating and curing of thermoset composite parts by pressing between a heated rigid mold and customized rubber-faced mold |
WO2016084824A1 (en) * | 2014-11-26 | 2016-06-02 | 東レ株式会社 | Carbon fiber mat, preform, sheet material, and molded article |
-
2019
- 2019-11-06 EP EP19207386.4A patent/EP3819104A1/en not_active Withdrawn
-
2020
- 2020-11-04 EP EP20800142.0A patent/EP4054828A1/en active Pending
- 2020-11-04 WO PCT/EP2020/080890 patent/WO2021089586A1/en unknown
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Publication number | Publication date |
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WO2021089586A1 (en) | 2021-05-14 |
EP3819104A1 (en) | 2021-05-12 |
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