EP4330004A1 - Dispositif, procédé et ensemble plaque-condensateur pour produire une pièce en mousse de particules - Google Patents

Dispositif, procédé et ensemble plaque-condensateur pour produire une pièce en mousse de particules

Info

Publication number
EP4330004A1
EP4330004A1 EP22725199.8A EP22725199A EP4330004A1 EP 4330004 A1 EP4330004 A1 EP 4330004A1 EP 22725199 A EP22725199 A EP 22725199A EP 4330004 A1 EP4330004 A1 EP 4330004A1
Authority
EP
European Patent Office
Prior art keywords
segments
mold
capacitor plate
capacitor
electrically
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
Application number
EP22725199.8A
Other languages
German (de)
English (en)
Inventor
Victor Romanov
Constantin KEMMER
Marc Norridge
Bastian Gothe
Jarkko Siltamäki
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kurtz & Co Kg GmbH
Original Assignee
Kurtz & Co Kg GmbH
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Kurtz & Co Kg GmbH filed Critical Kurtz & Co Kg GmbH
Publication of EP4330004A1 publication Critical patent/EP4330004A1/fr
Pending legal-status Critical Current

Links

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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
    • B29C44/44—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form
    • B29C44/445—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form in the form of expandable granules, particles or beads
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0861—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using radio frequency
    • 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
    • B29C33/02—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means
    • 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
    • B29K2021/00—Use of unspecified rubbers as moulding material
    • B29K2021/003—Thermoplastic elastomers
    • 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
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B29K2067/003—PET, i.e. poylethylene terephthalate
    • 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
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B29K2067/006—PBT, i.e. polybutylene terephthalate
    • 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
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B29K2067/04—Polyesters derived from hydroxycarboxylic acids
    • B29K2067/046—PLA, i.e. polylactic acid or polylactide
    • 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
    • B29K2823/00—Use of polyalkenes or derivatives thereof as mould material
    • B29K2823/04—Polymers of ethylene
    • B29K2823/06—PE, i.e. polyethylene
    • B29K2823/0658—PE, i.e. polyethylene characterised by its molecular weight
    • B29K2823/0666—ULMWPE, i.e. ultra low molecular weight polyethylene
    • 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
    • B29K2827/00—Use of polyvinylhalogenides or derivatives thereof as mould material
    • B29K2827/12—Use of polyvinylhalogenides or derivatives thereof as mould material containing fluorine
    • B29K2827/18—PTFE, i.e. polytetrafluorethene, e.g. ePTFE, i.e. expanded polytetrafluorethene
    • 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
    • B29K2871/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as mould material

Definitions

  • the invention relates to a device, a method and a capacitor plate set for producing a particle foam part.
  • the device, the method and the capacitor plate set are provided for the production of the particle foam parts using electromagnetic waves, with the foam particles being welded to form a particle sc ha material part by means of the electromagnetic waves.
  • the energy required for welding is applied to the foam particles by means of electromagnetic waves.
  • the device, the method and the capacitor plate set can be used in particular in the production of a particle foam part, in particular a particle foam part with a three-dimensional shape with varying thickness.
  • US Pat. No. 3,079,723 describes a process for sintering moist thermoplastic foam particles.
  • the particles are dielectrically heated and compressed at the same time.
  • Electromagnetic waves with a frequency of about 2 to 1000 MHz are applied.
  • the document GB 1,403,326 describes a method for welding expandable polystyrene foam particles. Particles with a aqueous solution and exposed to an electromagnetic field of 5 to 2000 MHz.
  • WO 01/064414 A1 discloses a method in which polymer particles made of polyolefins, which are wetted with a liquid medium, are heated with electromagnetic waves, in particular microwaves.
  • the temperature in the mold is regulated by controlling the pressure therein.
  • WO 2013/050181 A1 describes a method for producing particle foam parts, in which a mixture of foam particles and dielectric transfer liquid is heated by means of electromagnetic waves in order to fuse the foam particles to form a particle foam part. Radio waves or microwaves are used as electromagnetic waves.
  • the material of the foam particles is made of polypropylene (PP).
  • DE 10 2016 100 690 A1 discloses a device for producing a particle foam part, in which a mold has capacitor plates, each of which is formed from a plurality of segments. The distance between the segments and a mold space of the mold can be set individually.
  • a molding tool of the device comprises two mold halves, each comprising a capacitor plate.
  • One of the mold halves is designed so that it is movably mounted in the mold and the distance between the two mold halves can be varied.
  • a very high energy input into the foam particles which are located in a tool for this purpose, is required to weld foam particles with electromagnetic radiation.
  • the energy input into the foam particles should be as uniform as possible in order to achieve uniform heating and thus uniform welding of the foam particles.
  • the problem here is that the electrodes and the corresponding tool usually have different sizes.
  • the tool has to be changed depending on the product to be manufactured. Therefore, different tools are used in one device, which can differ in size.
  • the tool is usually a bit smaller than the electrode to place the tool entirely within the electric field of the plate capacitor.
  • the electrode therefore usually protrudes a little at the side of the tool. This creates an electric field that is not used.
  • the capacity of the capacitor is larger than necessary. As a result, the capacitor absorbs more charge and thus more energy than necessary.
  • particle foam parts that almost never have a constant thickness along their length and/or width. This makes the welding process more difficult, since it is difficult to achieve uniform and homogeneous welding of the particles over all areas of the particle foam part.
  • the applicant of the present patent application has developed the devices for welding foam particles by means of electromagnetic waves and the corresponding methods in such a way that it is able to produce larger numbers of foam particles using the first machines by welding the Produce foam particles by means of electromagnetic waves.
  • These devices and methods are based on the technology that is described in the publications DE 10 2016 100 690 A1 and DE 10 2016 123 214 A1 and in the German patent application no of the invention described below in its entirety, and in particular relating to the devices and methods as well as materials, reference is made in addition but not exclusively.
  • the object of the present invention is in particular to increase the efficiency of the energy input and to use the electric field more effectively in the production of particle foam parts by welding foam particles by means of electromagnetic waves.
  • the invention is also based on the problem of increasing the quality of particle foam parts that are produced by welding foam particles together using electromagnetic fields, even if they have a complex three-dimensional geometry and, in particular, a different thickness.
  • a first aspect of the invention relates to a device for producing a particle foam part.
  • the device comprises a molding tool defining a molding space, at least two capacitor plates are arranged adjacent to the molding space, which are connected to a radiation source for electromagnetic radiation, wherein the electromagnetic radiation source is adapted to emit electromagnetic radiation, and the molding tool is formed from at least two mold halves, with at least one of the two capacitor plates being formed from a plurality of segments, so that the surface of the capacitor plate field with the plurality of segments can be adapted in the mold space depending on the shape of the product to be melted.
  • the capacitor plate formed from segments is designed, for example, as a segmented electrode. It can be composed of several sections. This is relatively easy to do, particularly in the case of a flat electrode or capacitor plate. However, it is possible not only with planar but also with contoured electrodes, such as electrodes for making fish boxes.
  • the segments are shaped in such a way that by removing and/or adding the individual segments to form the capacitor plate, the shape and size of the capacitor plate, and in particular its dimensions, can be adapted to the shape of the mold.
  • the segments of the capacitor plate are preferably electrically and mechanically connected to one another in a detachable manner. This allows individual segments to be removed or added to adapt the area of the capacitor plate to the size of the mold.
  • An electrically conductive connecting element can be provided which electrically connects two or more segments to one another at their edges.
  • electrically conductive metal elements such as copper or brass foils can be used, against which the edges of the segments of the electrodes are clamped so that there is an electrical connection to all segments of the electrodes.
  • the segments can have areas at their edges which interlock when the segments are in the assembled state.
  • the electrical and mechanical connection can be produced particularly reliably and relatively inexpensively at the joints of the segments.
  • the edges or areas can be designed as shiplap folds, for example.
  • the segments can also be provided in an unlocked manner, in particular without such locking areas, which can be advantageous in order to enable in-mold assembly, ie assembly of the segments (or adding or removing one or more segments) without the mold/ having to remove the capacitor plates.
  • the segments are removably attached to an insulator.
  • the insulator serves to hold the segments in place.
  • the insulator is preferably suitable for high voltage and does not cause any significant losses in the HF radiation, as it would otherwise heat up.
  • the material used should also not show any significant reaction to the electromagnetic field used in terms of its field conductivity and its dielectric loss, since this would in turn lead to undesirable heating.
  • a dielectric material with a preferably low dissipation factor and a low dielectric constant is preferred.
  • a ceramic material and/or a plastic material can be used.
  • dielectric polymers that can be used include: PEEK, PTFE, PE, PS, PET.
  • ceramic materials that can be used include: alumina, aluminum nitride, aluminum silicates.
  • the segments of the electrode or the capacitor plate can be attached to the insulator, for example by means of screws.
  • other fastening means such as plug connections, bolts, clamping elements, etc., can also be suitable for fastening the segments to the insulator.
  • At least one segment of the capacitor plate formed from the segments is electrically connected to the radiation source.
  • the segments of the capacitor plate can be permanently attached to an insulator and can be individually switched on or off to adjust the size of the capacitor plate. This is possible in a relatively simple manner, in particular, when the segmented capacitor plate is planar, or also when two planar, segmented capacitor plates form the capacitor for impinging the particles with radiation.
  • the segments are preferably electrically insulated from one another and are each connected separately to the radiation source, for example via a high-frequency line.
  • the radiation source is in particular a high-frequency generator.
  • the segments are each connected to a tunable resonant circuit and can be switched on or activated or switched off or deactivated individually or in groups by tuning the respective resonant circuit.
  • the segments each form a partial capacitor which is each connected to the tunable resonant circuit.
  • Each supply line is assigned a control capacitor with which the energy supplied via the respective line can be set independently of one another. In this way, by controlling the energy supply on the individual lines, it can be set which segment of the capacitor is operated. By switching individual segments on and off by means of resonant circuit tuning, the size of the capacitor plate can be adapted to the size of the mold with regard to its radiation-emitting surface. As a result, it is not necessary to mechanically remove or attach individual segments, depending on the mold used, in order to adjust the surface of the capacitor plate.
  • the segments together form a contoured capacitor plate.
  • the segments can in particular be arranged on both sides of the mold space and in particular form a segmented capacitor plate there.
  • the segments can also be arranged on only one side of the mold space and form a segmented capacitor plate there.
  • a continuous capacitor plate for example, can be arranged on the other side of the mold space.
  • an electrically conductive area of the mold or an electrically conductive mold half can serve as a capacitor plate, which lies opposite the segmented capacitor plate.
  • an electrically non-conductive mold half is preferred because it makes it easier to set up a uniform electric field.
  • the use of an electrically conductive mold half would entail the risk that the component produced would burn in the areas adjacent to this mold half, so that a non-conductive material is also preferred from this point of view. If both mold halves were electrically conductive, one mold half would have to be connected to an RF radiation line, which would be relatively difficult or very expensive to do.
  • At least one of the capacitor plates formed from the segments is advantageously electrically connected to the radiation source, while for example the other capacitor plate or its segments are electrically grounded or connected to ground.
  • the segments can each have a geometry which, when the segments are combined, results in a capacitor plate whose geometry is adapted to the geometry of the mold.
  • the segments can be rectangular, preferably with different dimensions, in order to form rectangles of different sizes as a capacitor plate by combining several segments depending on the size of the tool to be irradiated.
  • edges of adjacent segments advantageously run parallel to one another in order to form the capacitor plate together by combining several segments.
  • an arrangement of the individual segments is advantageous in which a central square segment is provided and further additional segments extend along the sides of the square segment. You can use this to display rectangles of different sizes by combining several segments. A further ring of additional segments can also be provided.
  • the segments can be designed as sheet metal parts, for example.
  • the segments are preferably flexible. They are advantageously made of a metal with good electrical conductivity or a metal alloy with good electrical conductivity.
  • a capacitor plate set is provided for a device for producing a particle foam part.
  • the capacitor plate set includes at least a first capacitor plate segment that can be attached to an insulator and a Has a connection area that can be connected to a radiation source for generating electromagnetic radiation, and one or more second capacitor plate segments, wherein the first capacitor plate segment and the second capacitor plate segments are designed to jointly form a capacitor plate, the size of which corresponds to the size of a mold for Fier ein of the particle foam part is adjustable.
  • the capacitor plate segments form a set of several objects that belong together to form at least one or more segmented capacitor plates, the size of which can be adapted to the size of the tool that contains the foam particles.
  • the capacitor plate segments can preferably be electrically and mechanically connected to one another in a detachable manner.
  • the second capacitor plate segments can also each have a connection area for connection to a radiation source for generating electromagnetic radiation.
  • Each capacitor plate segment can be designed in such a way that it is electrically insulated from the other capacitor plate segments in the capacitor plate formed therefrom and can in particular be switched on or off by a tunable resonant circuit.
  • the capacitor plate set is preferably designed for use in a device according to the invention.
  • a third aspect of the invention relates to a method for producing a particle foam part.
  • the method comprises the following steps: a.) Filling foam particles into a mold space of a mold, wherein at least two capacitor plates are arranged adjacent to the mold space, which are electrically connected to a radiation source for electromagnetic radiation to generate electromagnetic radiation; b. ) Welding of the foam particles by the electromagnetic radiation between the capacitor plates; and c.) demoulding; wherein d.) at least one of the two capacitor plates is formed from a multiplicity of segments and the area of the at least one capacitor plate is adapted to the size of the mold by combining the radiation-generating segments.
  • the foam particles are heated in the mold so that they fuse to form the particle foam around the fabric part. Heat is supplied to the foam particles by means of electromagnetic RF radiation.
  • the segments are releasably electrically and mechanically connected to one another in order to combine them with one another.
  • the segments can be arranged electrically insulated from one another and switched on or off, for example by tuning an oscillating circuit connected to the segment, in order to combine them with one another.
  • This allows the area of the capacitor plate that emits radiation to be adjusted without having to mechanically remove or mechanically add segments. In particular, this eliminates the mechanical separation or connection of segments to the radiation source when adjusting the capacitor plate area, which would require a great deal of effort.
  • the segments each form a partial capacitor.
  • a device according to the invention and/or a capacitor plate set according to the invention is used to carry out the method.
  • the foam particles are preferably expanded, thermoplastic materials, in particular formed from polyurethane (PU), polylactate (PLA), polyethylene block amide (PEBA) or from polyethylene terephthalate (PET). They mainly consist of polyurethane, polylactate (PLA), polyethylene block amide (PEBA), polyethylene terephthalate or a mixture of these materials.
  • the foam particles preferably consist of 90% by weight of one or a mixture of these materials.
  • These foam particles are particles that form a so-called pearl foam, which is also known in the art as pellet / particle foam is called.
  • the foams obtained from the use of continuous foam particles are given the designation "e" to denote the bead shape of the polymeric foam component, e.g. eTPU.
  • the foam particles made from these materials are primarily heated by direct absorption of the RF radiation. This means that the heat is not or only to a small extent via a heat-transferring medium such.
  • B. water which absorbs the RF radiation and delivers it to the foam particles, is heated.
  • the immediate absorption of the RF radiation is very efficient and also allows the welding of foam particles made of materials such as polyethylene terephthalate (PET) with a softening temperature of over 200°C (usually around 260°C). , which is not possible by heating with an aqueous heat transfer medium.
  • PET polyethylene terephthalate
  • the softening temperature of over 200°C (usually around 260°C).
  • the use of such heat transfer media is avoided or reduced, as a result of which the quality of the end product is improved.
  • the electromagnetic RF radiation preferably has a frequency of at least 30 kHz or at least 0.1 MHz, in particular at least 1 MHz or at least 2 MHz, preferably at least 10 MHz.
  • the maximum frequency is usually 300 MHz.
  • Specific (centre) frequencies that can be used and for which radiation sources are readily available commercially are e.g. B. 6.78MHz, 13.56MHz, 27.12MHz, 40.68MHz.
  • (middle) frequencies of 2.45 GHz or 5.8 GHz can also be used.
  • the capacitor plates are preferably arranged on the mold or mold area, which is otherwise made of an electrically insulating material.
  • a high-frequency voltage with an amplitude of approximately at least 1 kV up to a few kV, preferably at least 10 kV and in particular at least 20 kV, is applied to the capacitor plates.
  • a power in the range of 10 kW to 60 kW can be transmitted to the foam particles located in the mold space.
  • large-volume particle foam parts can also be reliably produced with very short cycle times of around 30 seconds to 2 minutes.
  • the foam particles can be compressed in the mold.
  • the tool is designed as a crack gap forming tool, for example.
  • the foam particles are mechanically compressed, in addition to the effect of their thermal expansion.
  • the mold is preferably made of a material that is essentially transparent to the RF electromagnetic radiation used, such as e.g. B. polytetrafluoroethylene (PTFE), polyethylene, especially UHMWPE, polyetherketone (PEEK) and other materials transparent to RF radiation.
  • PTFE polytetrafluoroethylene
  • polyethylene especially UHMWPE
  • PEEK polyetherketone
  • semi-transparent materials can also be used, such as polyethylene terephthalate (PET), polyoxymethylene (POM) or polyketone (PK).
  • the electromagnetic radiation source is designed as part of a generator resonant circuit.
  • Lines for guiding the electromagnetic waves form a tool resonant circuit together with each pair of segments forming a split capacitor.
  • the tool resonant circuit can be tuned by changing an inductance or a capacitance and forms a tunable resonant circuit through which the transmission of the power can be specifically blocked or released.
  • a control device for controlling the tunable oscillating circuit is designed such that the power supply from the generator oscillating circuit to the tool oscillating circuit, which is designed as a tunable oscillating circuit, is switched on or enabled or interrupted by its tuning.
  • the segment in question is added to or removed from the capacitor plate, which is formed from a plurality of segments and which applies electromagnetic radiation to the mold during the welding process.
  • the power that can be transmitted by switching on by tuning the resonant circuit is in particular in the range from 25 kW to 60 kW, depending on the dimensioning of the generator and the lines with which the generator resonant circuit is connected to the tunable resonant circuit.
  • One of the two capacitor plates may be electrically connected to ground in all of the implementations of the various aspects of the invention discussed thus far.
  • the other capacitor plate is connected directly to the radiation source either itself or through one or more of its segments, the radiation being applied as electromagnetic waves to that capacitor plate with respect to ground.
  • a fourth aspect of the present invention which can be combined with the first, second and/or third aspect of the invention described above and all their possible options, modifications and embodiments (unless this is physically or technically precluded), is achieved by an apparatus for Production of a particle foam part provided.
  • the device comprises: a.) a mold formed from at least two mold halves, which defines a mold cavity; b.) at least two capacitor plates located adjacent to the mold cavity; wherein c.) at least one of the capacitor plates is connected to a radiation source; and wherein d.) at least one of the capacitor plates comprises a plurality of segments having an adjustable distance from the mold space.
  • the placement of the capacitor plates "adjacent" to the mold cavity does not mean that the capacitor plates are in direct contact with the mold cavity or form the walls of the mold cavity. Rather, it means that the capacitor plates are arranged "around" the mold space and at a distance from it that makes it possible to flood or irradiate the mold space with an alternating electromagnetic field that is suitable for the desired welding of the foam particles in the mold space generate.
  • components or parts e.g. B. of the mold are arranged between the capacitor plates and the mold space (see e.g. the detailed discussion of possible embodiments with reference to the figures in FIGS following sections), and the shape and dimensions of the mold space are defined by the mold tool and not by the capacitor plates themselves (making it generally possible to use different mold tools with different mold cavities between the same set of capacitor plates).
  • the multiple segments are designed in such a way that manual or automatic changes in shape of the respective capacitor plate (also called “electrode” below) are possible. These changes in shape serve to locally control the electric field strength within the mold space and thus control the heating of the material at this point, as will be explained in more detail below.
  • This modularity brings with it both manufacturing and product advantages.
  • the device presented here enables flexible changes to the tool design, in particular with regard to the distance between the active and passive electrodes/capacitor plates and, above all, to a grid resolution.
  • the change can be made manually or actively, depending on the actuation selected.
  • the change can be set for the part being manufactured, or it can even be changed during the process to allow even more control than is currently possible.
  • the field strength can be increased or decreased locally, and thus the heating rate and the maximum temperature experienced by the target can be determined. This enables, for example, rapid adaptation to new mold geometries and locally coordinated part properties.
  • At least one of the electrode/capacitor plates is therefore divided into a collection of elements or segments (e.g. a lattice of such elements/segments) which can be moved parallel to the z-axis running in the direction from the electrode/capacitor plate to the mold space, but which are preferably still electrically connected to a main body of the electrode (be it the active or passive side, preferably the passive) which is then further connected to a radiation generator or ground (preferably ground potential, as this allows for a simpler construction ) connected is.
  • the distance between the electrode elements/segments and the mold space, and thus between the opposing electrodes/capacitor plates influences the local field strength in the gap between the two electrodes/capacitor plates and thus in the mold space.
  • This distance can be adjusted by any form of actuators and the distance control can be done at the level of the individual segments. In particular, it is possible to always keep all elements in electrical contact and not to disturb the electromagnetic fusion process through the segment control.
  • the segments can be electrically connected to an electrically conductive electrode main body.
  • the main electrode body can be grounded.
  • the capacitor plate that is connected to the radiation source can be a first capacitor plate on one side of the mold space
  • the capacitor plate that includes the multiple segments that have an adjustable distance from the mold space can be a second capacitor plate on an opposite side of the mold cavity.
  • an "active" capacitor plate connected to the radiation source and a “passive” capacitor plate containing the adjustable segments can be placed on opposite sides of the mold space and enclose the mold space between them, and by adjusting the spacing of the segments to the mold space, the distance between the two capacitor plates is also effectively changed locally. In the mold space, this leads to a change in the field strength distribution of the electromagnetic field flowing through the mold space and thus on the particle surfaces, which are welded under the influence of the electromagnetic field.
  • the distance between the segments and the mold space can be adjusted individually by mechanical and/or electrical adjusting means.
  • the segments can be arranged in a two-dimensional grid, in particular in a rectangular grid.
  • the grid density ie the number of adjustable segments per unit area
  • the grid density can also vary locally. For example, areas with different thicknesses to be produced can be arranged with segments having a higher density than in other areas of the particle foam part, in order to enable even better control of the welding process in these areas.
  • the segments can be provided as screws or pins which are adjustably connected to the main body of the electrode.
  • the screws can be z. B. be metal screws that are screwed into the electrode main body, and the electrode main body can also be made of metal or contain metal, z. e.g. aluminium.
  • a cover plate or cover layer made of electrically non-conductive material can also be arranged on the electrode main body and has openings in which the screws or pins are arranged.
  • Such a cover plate can serve to increase the stability of the arrangement of the segments themselves, e.g. B. by a lateral stabilization of the segments, especially when they are moved far out of the electrode main body (z. B. when the screws are screwed out of the base plate almost over their entire length).
  • it can also serve to create a stable platform on which other parts of the mold that lie between the electrode/capacitor plate and the mold space can rest. Without this plate or layer, the adjustable position of the segments would result in a varying bearing surface for the adjacent components of the mold, which not only requires a more complicated construction, but can also be detrimental to the stability of the tool.
  • Such a cover plate can consist of or comprise an electrically insulating cover.
  • the cover plate preferably consists of one or more of the following materials: polytetrafluoroethylene, PTFE, polyethylene, PE, in particular ultra high molecular weight polyethylene, UHMWPE, polyetherketone, PEEK, a thermoplastic, a thermoset, polyethylene terephthalate, PET, polyoxymethylene, POM, polystyrene, PS, an insulating mineral material.
  • each of the adjustable segments can be set to at least one of the following four positions: remote or electrically isolated, a low position, a middle position, a high position.
  • the adjustable segments can be electrically isolated, for example, by tuning a resonant circuit as disclosed herein in relation to the other aspects of the invention and/or by simple switch-like elements.
  • some or all of the segments may be positionally adjusted continuously (i.e., any position between a down position and an up position).
  • a limited number of predetermined positions can facilitate the operation of the device, while the possibility of continuous adjustment of the segment position (in the z-direction, i.e. towards and away from the mold space) increases the influence and control over the electromagnetic field strength distribution.
  • position means the position of the segments in the z-direction or in the flea. In other words, as the position of the segments is changed, their distance from the mold space changes.
  • the position of one or more of the segments i. H. its distance from the mold space and thus generally also from the opposite electrode/capacitor plate, the field strength distribution of the radiated electromagnetic field within the mold space.
  • a fifth aspect of the present invention which goes hand in hand with the fourth aspect and which can also make use of or be based on all the possibilities, embodiments and examples disclosed in connection with the first, second and/or third aspect of the present invention , is a method for producing a particle foam part, the method comprising: a.
  • introducing the particles into a mold space of a mold tool which is formed from at least two mold halves that delimit the mold space, wherein at least two capacitor plates are arranged adjacent to the mold space, wherein at least one of the capacitor plates is connected to a radiation source, and wherein at least one of the capacitor plates comprises a plurality of segments having an adjustable spacing from the mold space; b. ) irradiating the mold space with electromagnetic radiation emitted from the capacitor plates; and c.) locally adjusting a field strength distribution of the radiating electromagnetic field within the mold space by changing the adjustable distance of the segments to the mold space.
  • the change can take place before and/or during the irradiation of the mold space with the electromagnetic radiation.
  • the foam particles can consist of one or more of the following base materials: thermoplastic polyurethane (TPU), polylactate (PLA), polyamide (PA), polyether block amide (PEBA), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), thermoplastic polyester ether elastomer (TPEE).
  • TPU thermoplastic polyurethane
  • PLA polylactate
  • PA polyamide
  • PEBA polyether block amide
  • PET polyethylene terephthalate
  • PBT polybutylene terephthalate
  • TPEE thermoplastic polyester ether elastomer
  • such particles are also referred to in the art as particles of foamed material, where a foamed material is a material that has already been foamed (as opposed to a foamable material that can be foamed but has not yet been foamed). In other words, the particles already have a core of foamed material before they are placed in the mold.
  • the foam particles can therefore also be referred to as particles made from expanded (thermoplastic) polyurethane, e(T)PU, expanded polylactate, ePLA, expanded polyethylene block amide, ePEBA, and/or expanded polyethylene terephthalate, ePET. 4. Brief summary of the figures
  • FIG. 1 schematically shows an exemplary embodiment of a device for preparing a particle foam part
  • FIG. 2 shows a schematic representation of a segment arrangement which forms two opposing capacitor plates for the production of a particle foam part
  • FIG. 3 shows an arrangement of interconnected segments schematically as a sectional view
  • FIG. 4 shows an arrangement of segments which together form a capacitor plate, as a schematic view of the surface of the capacitor plate;
  • FIGS. 5-8 each show different devices for producing a particle foam part according to different embodiments of the invention.
  • FIG. 9 shows an arrangement for applying electromagnetic radiation to a mold according to a further embodiment of the invention in a schematic representation
  • FIG. 10 schematically shows an equivalent circuit diagram for an arrangement of segments which are each connected separately to a radiation source for generating electromagnetic radiation
  • FIG. 11 shows a switching device for connecting or disconnecting a capacitor plate segment to or from the capacitor plate for emitting electromagnetic radiation
  • FIG. 12 shows a control device for controlling the power supply in a circuit diagram.
  • Figure 13a-f show part of a device with a capacitor plate consisting of several segments that have an adjustable distance from the mold space, and corresponding measurement results obtained from a series of test runs with such a device.
  • the basic structure of a device 1 for producing a particle foam part is shown in FIG.
  • the device 1 comprises a material container 2 , a mold 3 and a line 4 which leads from the material container 2 to the mold 3 .
  • the material container 2 is used to hold loose foam particles.
  • the material container 2 has a base 5 , being connected to a compressed air source 7 via a compressed air line 6 in the base area.
  • a propulsion nozzle 8 is located in the conveying line 4 adjacent to the material container.
  • the driving nozzle 8 is connected to the compressed air source 7 by a further compressed air line 9 .
  • Compressed air fed to this driving nozzle 8 serves as driving air, since it enters the conveying line 4 through the driving nozzle 8 and flows in the direction of the mold 3 .
  • a negative pressure is generated at the driving nozzle 8 on the side facing the material container 2, which sucks foam particles out of the material container.
  • the delivery line 4 opens into a filling injector 10 which is coupled to the mold 3 .
  • the filling injector 10 is connected to the compressed air source 7 by a further compressed air line 11 .
  • the compressed air fed to the filling injector 10 is used, on the one hand, to fill the mold 3 in that the stream of foam particles is acted upon in the direction of the mold 3 by means of the compressed air.
  • the compressed air fed to the filling injector 10 can also be used to blow back the foam particles from the conveying line 4 into the material container 2 when the filling process at the mold 3 has been completed.
  • the mold 3 is formed from two mold halves 12,13. At least one mold space 14 is delimited between the two mold halves, in which the filling injector 10 opens for introducing the foam particles.
  • the volume of the mold space 14 can be reduced by moving the two mold halves 12, 13 together. When the mold halves 12, 13 are moved apart, a gap is formed between the mold halves 12, 13, which is referred to as the cracking gap.
  • Such a mold 3 is therefore also referred to as a crack-gap mold.
  • a capacitor plate 15, 16 is arranged on the mold halves 12, 13 in each case. These capacitor plates are each made of a highly electrically conductive material such. B. copper or aluminum.
  • the filling injector 10 is arranged on the mold half 13 . The filling injector 10 extends through a recess in the capacitor plate 16 which is mounted on the mold half 13 .
  • the two capacitor plates 15, 16 are each formed from a plurality of segments 85, 86 which are arranged adjacent to one another and are electrically and mechanically connected to one another.
  • the segments 85, 86 can be detached from one another.
  • the size of the first capacitor plate 15 formed from the segments 85 and the size of the second capacitor plate 16 formed from the segments 86 can be adapted to the size of the mold 3 by adding or removing individual segments 85, 86. In this way, molds 3 of different sizes can be arranged between the capacitor plates 15, 16. This makes it possible to generate electromagnetic radiation between the capacitor plates 15, 16 in a targeted manner only in the area of the mold space 14. In areas in which no electromagnetic radiation is required for welding foam particles, it is possible by removing individual segments 85, 86 to generate no electromagnetic radiation.
  • the segments 85, 86 are each attached to an insulator 80, 81 and form two opposing segment assemblies.
  • the insulators 80, 81 are used to hold the segments 85, 86 on two opposite sides of the mold 3.
  • the insulators 80, 81 with the segments 85 and 86 attached thereto are mounted such that they can be moved relative to one another.
  • the mold halves 12, 13 of the molding tool 3 together with the segmented capacitor plates 15, 16 lying laterally against them can be moved towards one another and away from one another.
  • the segments 85, 86 can also be attached to the mold 3 in such a way that they can be detached from the mold 3 and from one another.
  • both insulators 80, 81 or at least one can be omitted.
  • One of the segments 85 is connected to a generator 18, which forms an AC voltage source, via an electrical line 17 for the transmission of high-frequency voltages. Due to the electrical connection of the segments 85 to one another, they are subjected to high-frequency voltages and in this way form the capacitor plate 15.
  • the segments 86 on the opposite side of the shaped body 13, which form the capacitor plate 16, are electrically connected to ground 30, as is the generator 18. Since the segments 86 are also electrically connected to one another, only one of the segments is connected to ground 30 .
  • the generator 18 represents a radiation source for generating electromagnetic radiation.
  • the generator is preferably designed for generating RF radiation.
  • the generator can also be used to generate microwave radiation be formed, with larger mold spaces 14 with a RF radiation a much more uniform heating than with microwave radiation is possible.
  • most plastic materials absorb RF radiation much better than microwave radiation. Therefore, the use of RF radiation is preferred.
  • the mold halves 12, 13 each have a base body made of an electrically non-conductive and in particular for electromagnetic RF radiation substantially transparent material such.
  • the "substantially transparent material” is a material that can be penetrated by electromagnetic radiation, in particular RF radiation. However, this material can be designed with a certain absorption property for electromagnetic RF radiation, to a part of the electrical RF radiation to heat and to heat the mold halves 12, 13. This will be explained in more detail below.
  • the mold 3 can optionally be connected to a vacuum pump, so that a vacuum or vacuum can be applied to the mold space 14 . This negative pressure leads to the moisture contained in the mold space 14 being drawn off.
  • the capacitor plates 15, 16 are preferably provided with a cooling device.
  • the cooling device is formed by fans 20 which direct cooling air onto the side of the capacitor plates 15, 16 which is remote from the mold space 14. Cooling ribs can be provided to increase the cooling effect.
  • cooling lines can also be arranged on the capacitor plates 15, 16, through which a cooling medium is guided.
  • a cooling medium a liquid is preferably used, such as. B. water or oil.
  • the device 1 can also be designed with a steam generator and a steam supply to the mold space 14 and/or to the conveying line 4 in order to supply saturated dry steam to the mold space 14 for heating the foam particles and/or to wet foam particles on their transport from the material container 2 to the mold space 14 .
  • the foam particles that are in the Are material container 2 are wetted with water in liquid form, for this purpose 2 corresponding nozzles are arranged in the material container, which atomize the water.
  • Figure 2 shows schematically an enlarged partial view of the device 1 as a sectional view, but in this example, unlike in the example shown in Figure 1, as a variant, each of the segments 86 of the second capacitor plate is connected to the ground 30 is. Otherwise, the explanations for FIG. 1 also apply to FIG. 2 and vice versa, with elements of the same type being provided with the same reference symbols in the figures.
  • Fastening means 82 which are preferably designed as screws, are used to detachably fasten segments 85, 86 to the respective insulator 80 or 81.
  • Electrically conductive connecting elements 83 which are designed as electrically conductive, flexible metal elements in the form of foils and are designed, for example, as copper or brass foils, are used to electrically connect the segments 85 arranged next to one another, which form the first capacitor plate 15.
  • the connectors 83 electrically connect two or more adjacent segments 85 together at their edges.
  • the electrically conductive connecting elements 83 are pressed against the edges of the segments 85. This creates an electrical connection between the segments 85 for the capacitor plate 15 .
  • the connecting elements 83 are not absolutely necessary due to the grounding of the individual segments 86 in the second capacitor plate 16, but they can optionally be provided and arranged here in the same way as in the first capacitor plate 15.
  • the electrical line 17 designed as a high-frequency line connects one of the segments 85 to the generator 18 (see FIG. 1).
  • the segment electrically connected to the generator 18 is designed as a high-frequency connection segment or generator connection segment 87 . Due to the electrical connection between the segments 85 arranged next to one another, the entire segment arrangement 85 is electrically connected to the generator 18 and forms the first capacitor plate 15.
  • the segments 85 form a capacitor plate set 90 which, in cooperation, makes it possible to form the first capacitor plate 15 which can be connected to an HF radiation source and whose size can be adapted to the size of the mold 3 .
  • the capacitor plate 15 can also be adapted to the dimensions of the mold space 14 within the mold 3 .
  • Segment 87 which is designed as an HF connection segment and includes a connection area for line 17 for connection to generator 18, forms a first capacitor plate segment of capacitor plate set 90.
  • the other segments 85 form second capacitor plate segments for forming the capacitor plate 15.
  • the area of the capacitor plate 15 that can be produced by the capacitor plate set 90 can be adapted to the size of the mold 3 for the production of a particle foam part.
  • the first capacitor plate segment 87 and the second capacitor plate segments 85 are designed to be attached to the insulator 80 using the attachment means 82 .
  • the segments 86 of the second capacitor plate 16 arranged opposite the first capacitor plate 15 form further capacitor plate segments of the capacitor plate set 90.
  • the further capacitor plate segments 86 supplement the capacitor plate set 90 by enabling the production of a second capacitor plate and thus a complete capacitor. They are designed to be attached to the insulator 81 Both insulators 80, 81 can be part of the capacitor plate set 90.
  • a press 73 is also shown, which is connected via a cylinder-piston unit 76 to the insulator 80 which is arranged on one side of the mold 3 .
  • the opposite insulator 81 arranged on the other side of the mold 3 is stationary, so that the mold 3 can be pressed together between the two capacitor plates 15, 16, which are attached to the insulators 80, 81 on the respective side facing the mold 3 .
  • the foam particles located in the mold space 14 of the mold 3 designed as a crack-gap mold can be pressed together during the exposure to electromagnetic radiation.
  • the foam particles are not only pressed together due to their thermal expansion as a result of the electromagnetic heating, but also due to the pressing together of the two mold halves 12, 13 of the mold 3.
  • FIG. 3 shows a further possible connection of the segments 85 or 86 of the capacitor plates 15 or 16 arranged next to one another, as are shown in FIGS. 1 and 2 and in further embodiments to follow.
  • the segments 85, 86 have at their edges in each case edge regions 88 protruding from the segment body, which are designed in such a way that they engage in one another when the segments 85, 86 are joined together.
  • the edge areas 88 form a stepped fold at the joints of the segments 85, 86. In this way, a particularly reliable electrical and mechanical connection is produced between the segments 85, 86, which can also be implemented very cost-effectively.
  • FIG. 4 shows an example of an arrangement of the segments 85, 86, which form the capacitor plate 15 or the capacitor plate 16 and can be produced by the capacitor plate set 90.
  • the figure shows a view of the surface of the capacitor plate.
  • a central segment 89 is located centrally and is surrounded by additional segments 91 .
  • the central segment 89 is square educated.
  • the additional segments 91 each extend along one of the sides of the central segment to 89 and along one side of another additional segment.
  • a first additional segment 91 is provided, which extends along one of the sides of the square.
  • a second additional segment 91 is provided, which extends along another side of the square and along one side of the first additional segment 91, a third additional segment 91, which extends along another side of the square and along the second additional segment 91, and a fourth Additional segment 91 extending along the remaining side of the square and along two sides of the additional segments 91.
  • different rectangles can be formed as capacitor plate surfaces by combining several segments 85, 86.
  • further additional segments can be provided in order to supplement the arrangement or also to surround it in the manner of a further ring.
  • the central segment 89 can also be formed as a rectangle.
  • the molding tool 3 of the device 1 according to FIG. 5 is in turn formed from two mold halves 12, 13, each of which has a base body which consists of an electrically non-conductive material and, in particular, transparent to electromagnetic RF radiation.
  • This material is PTFE, PE, PEEK or another material that is transparent to RF radiation.
  • the mold halves 12, 13 delimit a mold space 14.
  • the mold space 14 has inner delimiting surfaces 19, which have a contoured shape that deviates from a flat surface.
  • the mold halves 12, 13 each have a planar outer surface 21 on which a capacitor plate 15, 16 is arranged in each case.
  • the space between the contoured boundary surfaces 19 and the outer surfaces 20 is filled with material that is transparent to electromagnetic radiation.
  • Three-dimensionally contoured particle foam parts can be produced with this molding tool 3, the shape of the particle foam part being defined by the inner boundary surfaces 19 of the mold halves 12, 13.
  • Such a mold 3 is particularly suitable for the production of small particle foam parts with a substantially uniform density.
  • the capacitor plates 15, 16 are flat and designed as described above with reference to FIGS.
  • the first capacitor plate 15 is formed from segments 85 lying against one another.
  • the second capacitor plate 16 is also formed from segments 86 adjacent to one another.
  • Each of the arrays of segments 85 and 86 is attached to an insulator 80 and 81, respectively, with fasteners 82, the segments 85 of the first capacitor plate 15 being mechanically and electrically conductively, releasably connected to one another, as explained above with reference to FIGS .
  • the segments 86 of the second capacitor plate 16 are mechanically and electrically conductive and detachably connected to one another.
  • the segments 58, 86 and optionally also the insulators 80, 81 are part of a capacitor plate segment set 90, as described above.
  • the problem with large or thick particle foam parts is that they heat up more in the center than in the edge area, which can destroy the particle structure.
  • the mold 3 can be temperature-controlled and/or additional heat can be supplied to the foam particles in the mold space 14 at the edge area, as described in DE 10 2016 100 690 A1.
  • a modification of the device shown which is explained in more detail below, makes it possible to switch off individual segments 85, 86 before the end of the welding process in order to prevent the foam particles arranged between the relevant segments from overheating.
  • the exemplary embodiments explained above each have planar capacitor plates 15, 16.
  • the molds 3 can be designed in such a way that the capacitor plates 15, 16 are adapted to the shape of the particle foam part to be produced or of the mold space 14.
  • the outer surfaces 21 of the mold halves 12, 13 are adapted to the contour of the corresponding inner boundary surfaces 19 of the mold halves 12, 13 in question.
  • Small structures of the inner boundary surface 19 are preferably smoothed on the outer surface 21 .
  • the mold 3 thus has contoured mold halves 12, 13, on the opposite outer surfaces 21 of which a correspondingly contoured, segmented capacitor plate 15, 16 rests, which is formed from a plurality of segments 85 or 86 and otherwise as above with reference to Figures 1 to 5 is formed described.
  • Such an adaptation of the shape of the capacitor plates formed from segments 85, 86 to the shape of the particle foam parts to be produced is expedient in particular in the case of shell-shaped particle foam parts.
  • Such shell-shaped particle foam parts are, for example, boxes or shells in the shape of segmented spheres.
  • insulators 80, 81 are used to hold the segments.
  • the insulators are adapted to the shape of the outer surfaces 20 of the mold halves 12, 13 on their sides facing the mold halves.
  • FIG. 7 shows a further embodiment in which the first capacitor plate 15 formed from segments 85 together with the insulator 80 and the pressing tool formed from the press 73 and the cylinder-piston unit 76 is designed as described above with reference to FIGS. In particular, reference is made to FIG. 2 and the associated description.
  • the mold 3 has a first mold half 12 and a second mold half 13, which form a mold space 14 between them, in which foam particles 29 to be welded are located.
  • first mold half 12 and second mold half 13 which form a mold space 14 between them, in which foam particles 29 to be welded are located.
  • the second mold half 13 or at least a portion thereof is electrically conductive or made of electrically conductive material.
  • the molding tool 3 can be used as part of the device 1, with the second mold half 13 serving as a second capacitor plate and being electrically connected to ground 30 for this purpose.
  • the second mold half 13 has a base body 24 made of an electrically conductive material.
  • This base body 24 consists, for example, of aluminum, copper or an electrically highly conductive alloy. It is optionally provided with an electrically insulating coating 28 and forms a bottom wall 31.
  • the electrically conductive base body 24 has an electrical connection in order to be able to be connected to the generator 18 or to ground 30.
  • the generator 18 (see FIGS. 1, 5 and 6) electrically connected to the segmented capacitor plate 15 by the high-frequency line 17 generates electromagnetic waves or an electrical alternating voltage with respect to the mass 30 which is present on the base body 24 of the second mold half 13 .
  • an electromagnetic alternating field in particular RF radiation, is formed in the mold space 14 between the segmented capacitor plate 15 and the base body 24 .
  • a circumferential side wall 32 of the second mold half 13 is made of an electrically non-conductive material, in particular a plastic material, and extends from the bottom wall 31, starting on the sides of the mold half 13, in the direction of the first mold half 12, as a result of which the mold cavity 14 is laterally delimited .
  • both the bottom wall 31 and the side wall 32 can be formed from the electrically conductive base body 24 .
  • the first mold half 12, which is arranged on the side of the mold 3 facing the segmented capacitor plate 15, consists of an electrically non-conductive material, as described above.
  • the first mold half 12 forms a stamp which can move into the flea space formed by the second mold half 13 and thus seals the mold space 14 tightly.
  • the tight seal between the two mold halves 12, 13 is at least so tight that foam particles 29 located therein cannot escape.
  • the mold space 14 is not necessarily sealed in a gas-tight manner.
  • the first mold half 12 has an inner boundary wall 34 that is contoured and defines the mold cavity 14 .
  • a plurality of webs 35 extend in the direction of the first capacitor plate 15 to an optional cover element 37.
  • the webs 35 serve to support the boundary wall 34.
  • cavities 36 are formed in the first mold half 12, which significantly reduces its mass to reduce.
  • the flea spaces 36 can be used to trim the male mold half 12 to affect the electromagnetic field in the mold space 14, in addition to the flexibility provided by changing or adjusting the area of the capacitor plate 15 through various combinations of segments 85.
  • a particularly uniform or also a desirable distribution of the field strength in the mold space 14 can be achieved by trimming.
  • Trimming bodies made of a dielectric material can also be inserted into the flea spaces 36 . Due to the polarizing properties of a dielectric, the alternating electromagnetic field is concentrated in the adjacent area of the mold space 14 by the dielectric lying in the path of the field lines. On the other hand, in areas along the path of the same field lines that are kept clear of the dielectric, the field is not concentrated in the adjacent area of the mold space 14, and is therefore weaker in this area of the mold space 14 than in an area of the mold space 14 in the adjacent a dielectric is arranged.
  • the electrical field can thus be additionally influenced in different ways by trimming bodies of different size, shape and permittivity.
  • the permittivity of a dielectric is greater than that of vacuum or air.
  • the two mold halves 12, 13 can be moved relative to one another by means of a press 73 and subjected to a predetermined force.
  • the press 73 is connected via a cylinder-piston unit 76 to the insulator 80, to which the first capacitor plate 15 formed from the segments 85 is fastened, as described above with reference to FIG.
  • the first mold half 12 is moved in the direction of the second mold half 13 by the movable segmented capacitor plate 15 by means of the press 73.
  • a passage opening for feeding in the foam particles 29 is arranged on the second mold half 13 and is referred to as the filling opening 33 .
  • a filling injector 10 (see FIG. 1) is connected to the filling opening 33 .
  • the filling injector 10 differs from conventional filling injectors in that it does not have a closing mechanism for closing the filling opening 33, as will be explained in more detail below.
  • the first mold half 12 has one or more through openings, not shown in the figure, for the escape of air.
  • the filling opening 33 and the ventilation openings are arranged on a section or area, in particular an edge area, of the second mold half 13 which is covered by the first mold half 12 when the mold 3 is in the closed state. Therefore, the filling opening 33 and the vent opening are automatically closed when the mold 3 is closed by inserting the first mold 12 into the cavity formed by the second mold 13 . As a result, it is not necessary for the filling injector 10 to have a closing mechanism with which the filling opening 33 is closed.
  • FIG. 8 shows a device 1 for producing a particle foam part according to a further embodiment, in which, similarly to FIG.
  • the first mold half 12 is electrically non-conductive and, as in the embodiment shown in FIG. Here, too, cavities 36 are formed between the webs 35 in order to influence the electromagnetic field in the mold space 14 between the two mold halves 12, 13, as explained in detail above.
  • the peripheral side wall 32 which laterally closes off the mold space 14, is on the first mold half 12 educated.
  • a region 38 of the electrically conductive second mold half 13 dips within the side wall 32 into the mold space 14 formed by the peripheral side wall and closes off the mold space 14 on this side, while it is closed on the opposite side by the boundary wall 34 of the first mold half 12 .
  • the foam particles 29 located in the mold space 14 are pressed together by the protruding area 38 when the two mold halves 12, 13 are pressed together by the segmented capacitor plate 15 which is pressed against the first mold half 12 by means of the press 73.
  • a filling opening 33 for filling in the foam particles 29, which opens into the mold space 14, is opened by moving the two mold halves 12, 13 apart and closed by moving the two mold halves 12, 13 towards one another, as above together with further details with reference to FIG 7 described.
  • Figure 9 shows another embodiment of the invention in which the segments of the capacitor plates are electrically insulated from one another.
  • the segments 85 of the first capacitor plate 15 formed therefrom are permanently attached to the insulator 80 , electrically isolated from one another, with each segment being separately connected to the generator 18 via a tunable oscillating circuit 40 .
  • Generator 18 is connected to ground 30 .
  • the segments 86 which form the second capacitor plate 16 are electrically connected to the ground 30.
  • FIG. The segments 86 are permanently attached to the insulator 81 . If, as in the case shown here, all segments 86 are grounded, it is not absolutely necessary to arrange the segments 86 electrically insulated from one another. It is also possible to design the second capacitor plate 16 to be continuous or not segmented or to be divided into segments and to connect it electrically to ground 30 .
  • the generator 18 may be connected to each of the segments 86 instead with ground 30. In this case, segments 86 are not connected to ground 30.
  • the insulators 80, 81 and the segments 85, 86 and the tunable resonant circuits 40 form a capacitor plate set 90.
  • the segments 85, 86 are designed as capacitor plate segments and can be designed as in the embodiments described above. They can also have a geometry and form a planar arrangement as described above.
  • the mold 3 can be designed as in one of the embodiments described above. Minor modifications may be required to arrange the capacitor plates 15, 16 as shown in FIG.
  • FIG. 10 schematically shows a simplified equivalent circuit diagram of the device according to FIG. 9
  • FIG. 11 shows a single device for controlling the electrical power supplied to the segment pairs 85, 86 in a schematically simplified circuit diagram.
  • Figure 11 shows an electrical circuit diagram of the generator 18 and the partial capacitor formed by the segments 85, 86, which encloses the mold halves 12, 13 and a line (hollow waveguide or coaxial line) 46 suitable for transmitting the electromagnetic waves, with which the electromagnetic waves are transmitted from the generator 18 to the tool part capacitor 85, 86 are shown.
  • the hollow waveguide forming line 46 is a coaxial airline having an electrically conductive inner tube and an electrically conductive inner tube Formed outer tube.
  • the coaxial airwire is dimensioned in such a way that high-voltage signals can be transmitted reliably.
  • the characteristic impedance is preferably set to about 50W.
  • An inductance 47 on the generator side and an inductance 48 on the tool side are drawn symbolically in this line 46 . These inductances are caused by the line itself, with the length of the respective line sections determining the magnitude of the respective inductance.
  • a tool-side capacitor 49 is connected in parallel with the respective tool part capacitor 85, 86. This capacitor 49 represents the electrical capacitance between the capacitor segment 85 and the housing 35 of the molding tool 3.
  • the tool capacitor 85, 86, the capacitor 49 and the tool-side inductance 48 form a tool resonant circuit 50.
  • a generator-side capacitor 51 is connected in series with the generator 18 and the generator-side inductor.
  • the generator-side capacitor 51 and the generator-side inductor 47 form a generator resonant circuit 52.
  • At least the generator-side capacitor 51 or the generator-side inductor 47 is designed to be variable, for example by providing a capacitor with variable-distance capacitor plates or by providing line sections of different lengths. It is also possible for both the generator-side capacitor 51 and the generator-side inductor 47 to be variable.
  • the generator-side capacitor 51 can be provided with a servomotor which, when actuated, changes the distance between the two capacitor plates, for example by moving one of the two capacitor plates in a straight line, with both capacitor plates always being parallel to one another, or by pivoting one of the two capacitor plates.
  • the resonant frequency of the generator resonant circuit 52 can be changed or tuned. If the resonant frequencies of the generator oscillating circuit and the tool oscillating circuit match, then the maximum electrical power is transmitted from the generator 18 to the tool oscillating circuit 50 and thus to the tool part capacitor 85, 86.
  • the transmission of the electrical power can be controlled in a targeted manner, with the greater the difference between the resonant frequencies of the two resonant circuits 50, 52, the lower the transmitted power.
  • the tuning of the generator resonant circuit 52 can thus be used in a targeted manner to adjust the electrical power introduced into the mold space 14 .
  • the resonant frequency of the generator resonant circuit 52 is changed. It is equally possible to change the resonant frequency of the tool resonant circuit 50. This has the same effect with regard to the transmission of the electrical power. However, it is more difficult to provide a variable capacitor or variable inductance on the tool side than on the generator side.
  • the segments 85, 86 thus each form a tool capacitor or tool part capacitor, which is separately connected to the generator 18 via its own tunable resonant circuit 40.
  • the oscillating circuit circuit 40 thus includes the tool oscillating circuit 50 and the generator oscillating circuit 52.
  • the tool capacitors 85, 86 can be separated individually or in groups by changing the resonant frequency of the generator 18, so that no power or hardly any power is generated it is transmitted. In this way, they can be switched on or activated in the radiation-emitting capacitor plate segments 85 or 86 by changing the resonant frequency of one of the two resonant circuits 50, 52, or removed from or deactivated by it.
  • the resonant circuit circuit 40 forms a switching device 41 for connecting or disconnecting a capacitor plate segment 85 to or from the capacitor plate 15.
  • the segments 85, 86 can be connected or disconnected individually or in groups as partial capacitors in order to form the capacitor 15, 16 .
  • the electromagnetic radiation source 18 is part of a generator resonant circuit 52, while lines for guiding the electromagnetic waves form a tool resonant circuit 50 together with the respective segment pair 85, 86, which forms a partial capacitor.
  • the resonant frequency of the tool resonant circuit 50 can be tuned and forms a tunable resonant circuit.
  • the regulating or control device for controlling the tunable oscillating circuit is designed in such a way that the power supply from the generator oscillating circuit to the tool oscillating circuit, with one of the two oscillating circuits being designed as a tunable oscillating circuit, is switched on or enabled by tuning it or is interrupted.
  • the segment in question is added to or removed from the capacitor plate, which is formed from a plurality of segments and which applies electromagnetic radiation to the mold during the welding process.
  • the size of the capacitor plate can be adapted to the size of the mold with regard to its radiation-emitting surface. As a result, it is not necessary to mechanically remove or attach individual segments, depending on the mold used, in order to adjust the surface of the capacitor plate. It is also not necessary to mechanically interrupt or mechanically switch the lines 46 between the generator 18 and the individual segments 85 .
  • FIG. 12 shows a device for controlling the electrical power supplied to the tool capacitor 15, 16 in a schematically simplified circuit diagram.
  • the generator 18 is connected to the tool capacitor 15, 16.
  • a measuring capacitor 53 is connected in parallel with the tool capacitor 15 , 16 , the electrical capacitance of which is a fraction of the electrical capacitance of the tool capacitor 15 , 16 .
  • the measuring capacitor 53 is connected to a voltage measuring device (voltmeter) 55 via a coaxial line 54 .
  • a diode 56 is preferably connected in parallel with the measuring capacitor 53 .
  • the coaxial line 54 is connected in series with an inductor 58, which is used to filter high-frequency signals.
  • the measuring unit formed from the measuring capacitor 53 and the diode 56 is separated from the tool capacitor 15 , 16 by means of an isolating capacitor 59 .
  • the isolating capacitor has a high dielectric strength.
  • the capacitance of the isolating capacitor 59 is smaller than the capacitance of the measuring capacitor 53. As a result, a higher voltage drops across the isolating capacitor than across the measuring capacitor 53.
  • the ratio of the capacitance of the isolating capacitor 59 to the capacitance of the measuring capacitor 53 is preferably 1:100 or 1:1,000 or 1:10,000.
  • the voltage present at the tool capacitor 15, 16 in the measuring unit 53, 56 is reduced in such a way that it is within a measuring range of the voltage measuring device 55 and can be reliably detected by it.
  • a voltage drops across the measuring capacitor 53 which corresponds to the voltage present at the tool capacitor 15, 16 and is reduced in accordance with the ratio of the capacitance of the measuring capacitor 53 with respect to the capacitance of the isolating capacitor 59.
  • the diode 56 thus forms a rectification of the voltage occurring at the measuring capacitor 53 .
  • This measurement voltage is measured with the voltage measurement device 55 and converted into a measurement signal.
  • the measurement signal is forwarded to a control device 57, which automatically controls generator 18 to deliver a predetermined electrical power in order to generate a specific voltage on the tool capacitor or a specific measurement voltage on the measuring capacitor, which is a fraction of the voltage on the tool capacitor.
  • the device shown in FIG. 11 can be further developed such that for several or all pairs of segments 85, 86 a device for controlling the electrical power supplied to the capacitor formed by the pairs of segments 85, 86 according to FIG. 12 is provided.
  • This allows the power of the individual pairs of segments 85, 86 to be regulated individually and the effective size of the tool capacitor to be set without moving parts.
  • No calibration of the oscillating circuits generator oscillating circuit, tool oscillating circuit
  • the oscillating circuits generator oscillating circuit, tool oscillating circuit
  • foam particles are filled into a mold space 14 of a mold 3 .
  • Adjacent to the mold space 14 are two capacitor plates 15, 16 which are electrically connected to a radiation source 18 for electromagnetic radiation and generate electromagnetic radiation.
  • the capacitor plates 15, 16 or at least one of them is formed from a plurality of segments 85, 86.
  • the area of the capacitor plate 15, 16 is adapted to the size of the mold 3 by combining an appropriate number of the radiation-generating segments 85, 86, respectively.
  • the foam material particles are welded to one another by the electromagnetic radiation between the capacitor plates 15, 16.
  • the foam particles in the mold 3 are heated by the electromagnetic radiation, that is to say heat is supplied to the foam particles by means of electromagnetic RF radiation. As a result, they are welded to form a particle foam part.
  • the segments 85, 86 are releasably connected electrically and mechanically to combine them together.
  • the segments 85, 86 are arranged such that they are electrically isolated from one another.
  • the segments 85, 86 of the capacitor plate 15, 16 are switched on or activated therein or switched off or deactivated. As a result, they are combined with one another depending on the size and geometry of the mold 3 .
  • the area of the capacitor plate 15, 16, which emits electromagnetic radiation can be adapted to different molds 3.
  • segments 85, 86 it is not necessary for segments 85, 86 to be mechanically removed or mechanically added when changing the mold 3.
  • different molds can be electromagnetically irradiated one after the other in a very short time.
  • a device such as that shown in the various embodiments in FIGS. 1 to 11 is used, for example, to carry out the method.
  • a capacitor plate set 90 as described above is used to carry out the method.
  • Figures 13a-f show (part of) a device 1 with a capacitor plate 16, which consists of a number of segments 86 which have an adjustable distance d from the mold space 14, as well as corresponding measurement results obtained from a series of test runs with such a device 1 were won.
  • the general structure of the device 1 can be designed the same or similar to all other devices discussed here so far (in particular embodiments of the device 1). All the options, embodiments, modifications and features already discussed can therefore also be used in or combined with the device 1 which will now be described with reference to Figures 13a-f (obviously as far as this is physically and technically possible). This compatibility between the various disclosed aspects and embodiments is also confirmed by the fact that the same reference numbers as above are used for functionally identical or at least functionally similar or equivalent elements and components.
  • the disclosed device 1 can be used in particular to produce a particle foam part. It comprises a mold 3, which is formed from (at least two) mold halves 12 and 13.
  • the mold 3 defines a mold space 14 which is delimited by the two mold halves 12 and 13 (see in particular FIG. 13a).
  • Particles 29 made of foamed or expanded material e.g. particles eTPU or one of the other materials mentioned here
  • the device further comprises (at least two) capacitor plates 15 and 16 which are arranged adjacent to the mold space 14 .
  • “Adjacent” here means that the two capacitor plates 15 and 16 are arranged on two opposite sides of the mold space 14 and enclose the mold space 14 between them, so that the electromagnetic radiation emitted by the capacitor plates 15 and 16 flows through the mold space 14 and to the desired Welding of the foam particles 29 leads.
  • the other capacitor plate here the second capacitor plate 16
  • the other capacitor plate consists of several segments 86, which have an adjustable distance d to the mold space 14, ie their position along the z-direction (which is indicated in Figures 13a and 13d) can be changed, so that the distance d of the radiation-emitting surface of a respective segment 86 to the mold space (measured, for example, in relation to a wall of the mold space 14 or a specific reference point within the mold space 14) changes. Consequently, the distance between the two capacitor plates 15 and 16 also changes locally by adjusting the position of a segment 86.
  • the distance d between the segments 86 and the mold space 14 can be adjusted individually by mechanical and/or electrical adjusting means (e.g. by Fland or by a wrench, or by an electric motor, or a linear actuator, or by a motor-driven gearbox, etc., depending on the specific configuration of the segments 86).
  • mechanical and/or electrical adjusting means e.g. by Fland or by a wrench, or by an electric motor, or a linear actuator, or by a motor-driven gearbox, etc., depending on the specific configuration of the segments 86).
  • segment 86a For one of the segments, denoted as segment 86a in FIG. Both values change when the position of the segment 86a is changed in the z-direction.
  • the segments 86 are electrically connected to an electrically conductive main electrode body 100, which in the embodiment shown and discussed herein is at ground potential and constructed as a metal block. However, in other cases it may instead be connected to the radiation generator and the opposite capacitor plate may be grounded.
  • Aluminum is one possibility because it is comparatively light in weight and easy to process.
  • the segments 86 are provided as screws (e.g., but pins are also possible) which are adjustably connected to the electrode main body 100.
  • the screws 86 are metal screws that are screwed into corresponding threads of the electrode main body 100 .
  • the segments/screws 86 are arranged in a two-dimensional grid, in the embodiment of Figures 13a-f a square grid. This grid is indicated by dashed lines 130 in FIGS. 13b and 13c.
  • Other types of trellis are also possible, e.g. B. rectangular, triangular or hexagonal grids or "mixed" grids comprising different geometric shapes.
  • the grid density i.e. the number of adjustable segments/screws 86 per unit area
  • the capacitor plate 16 is mounted with its electrode main body 100 at its four corners on four aluminum blocks 120, which a certain distance from the floor and make room for the screws 86 to be fully screwed in, i. H. in its lowermost position, protrude from the underside of the electrode main body 100.
  • the highest achievable position is when the screws 86 are almost completely unscrewed from the electrode main body 100, but not completely.
  • a small amount of clearance is generally maintained to avoid inadvertently loosening one of the screws 86 from the electrode main body 100 and/or a general loss of stability as the respective screw 86 over the electrode main body 100 is approached at its maximum extent.
  • a cover plate 110 of electrically non-conductive material is placed on the electrode main body 100 (see Figure 13c; in Figure 13b the cover plate is removed to reveal the arrangement of the screws 86) and has openings in which the screws 86 are placed. This not only serves to stabilize the screws 86 when they are in a medium or, in particular, high position, i.e. screwed far out of the main electrode body 100. It also ensures a stable and level support surface for the adjacent components of the device 1, in particular the mold 3 (see Figures 13a, 13c, 13d, 13e and 13f).
  • cover plate 110 can generally consist of or comprise an electrically insulating cover plate.
  • the cover plate is preferably 110 made of one or more of the following materials: polytetrafluoroethylene, PTFE, polyethylene, PE, in particular ultra high molecular weight polyethylene, UHMWPE, polyetherketone, PEEK, a thermoplastic, a thermoset, polyethylene terephthalate, PET, polyoxymethylene, POM, polystyrene, PS, an insulating mineral material. In the case shown in Figure 13e, it is made of PTFE.
  • each of the adjustable segments/screws 86 can be set to one of at least four positions: removed (e.g., screwed out of the electrode main body 100) or electrically isolated, a low position, a middle position, a high position Position.
  • removed e.g., screwed out of the electrode main body 100
  • a middle position e.g., a high position Position.
  • adjustable segments which are designed as screws 86, it is also possible to continuously change their position in the z-direction by screwing them in or out to the desired degree (of course within the limits specified by the lowest and highest position) .
  • a limited number of predetermined positions to which the segments/screws 86 are set may facilitate the operation of the device 1.
  • exemplary screws set to low, medium and high positions are designated by reference numerals 861 (for low), 86m (for medium) and 86h (for high), respectively .
  • Figure 13d as indicated by the dashed ellipse 86x, one of the screws has been completely removed (alternatively, it could be electrically isolated from the capacitor plate 16/ground potential).
  • adjusting the position of one or more of the segments/screws 86 affects the field strength distribution of the radiated electromagnetic field within the mold space 14.
  • FIG 13d there are four areas or positions p1, p2, p3 and p4 within the mold space 14 shown schematically. Below these areas, the screws 86 are mounted in different positions/fleas. At the position pl are, for example Screws placed between the middle and the bottom position directly below it, at position p2 there is no screw at all under it (because the screw at position 86x was removed), at position p3 there are screws between the middle and the bottom position attached directly below it, and at position p4, screws are attached between the middle and top positions directly below it. In this way, the distribution of the electrical field strength and thus the temperature and the welding conditions at the various positions p1 to p4 can be adjusted and controlled.
  • test results shown in Figures 13e and 13f provide further insight into this aspect.
  • Various configurations of the device 1 used to study the flow rates and temperatures within a mold 3 at various positions of the screws 86 in the capacitor plate 16 are shown schematically on the left-hand side of the two figures.
  • two reference positions within the mold were considered, labeled P1 and P2, P3 and P4 and P5 and P6 in Figures 13e-f, one in the front part of the tool (see P1, P3 and P5) and one in the back of the tool (see P2, P4 and P6).
  • the x-axis in the traces on the right of Figures 13e-f shows time (the distance between two adjacent dashes or grid lines on the x-axis corresponds to about 43 seconds in Figures 13e and 13f), and the y-axis Figure 12 shows the temperature (ranging from 20°C to 140°C in Figures 13e and 13f).
  • a larger maximum temperature compared to the setting of the Screw(s) 86 in the low position 86I.
  • the shape of the other capacitor plate i.e. here the capacitor plate 15, which is connected to the radiation source, can also be at least partially adapted to the geometry of the part to be produced.
  • This "conventional and static” approach to adjusting the field distribution can thus supplement the “dynamic” adjustment options provided by the adjustable distance d segments 86 from the mold space 14 disclosed herein.
  • a fifth aspect of the present invention which goes with the fourth aspect Fland in Fland and which can also make use of or fall back on all possibilities, embodiments and examples disclosed in connection with the first, second and/or third aspect of the present invention, is a method for producing a particle foam part from foam particles 29, the method comprising: a. ) Introduction of the particles 29 into a mold space 14 of a mold tool 3, which is formed from at least two mold halves 12, 13, which delimit the mold space 14, with at least two capacitor plates 15, 16 being arranged adjacent to the mold space 14, with at least one of the capacitor plates 15 connected to a radiation source, and wherein at least one of the capacitor plates 16 has a plurality of segments 86 which are an adjustable distance d from the mold space 14 to have; b.
  • the change can take place before and/or during the irradiation of the mold space 14 with the electromagnetic radiation.
  • the foam particles 29 can consist of one or more of the following base materials: thermoplastic polyurethane (TPU), polylactate (PLA), polyamide (PA), polyethylene block amide (PEBA) and/or polyethylene terephthalate (PET), polybutylene terephthalate (PBT); thermoplastic polyester ether elastomer (TPEE).
  • TPU thermoplastic polyurethane
  • PLA polylactate
  • PA polyamide
  • PEBA polyethylene block amide
  • PET polyethylene terephthalate
  • PBT polybutylene terephthalate
  • TPEE thermoplastic polyester ether elastomer
  • these foam particles are particles that form a so-called beaded foam, which is also known in the art as pellet/particle foam.
  • the foams derived from the use of connected foam particles are given the notation "e” to denote the bead shape of the polymeric foam component, e.g. eTPU.
  • Example 2 The device according to Example 1, wherein the segments are electrically connected to an electrically conductive electrode main body (100).
  • cover plate is made of or comprises an electrically insulating cover, preferably wherein the cover plate is made of or comprises one or more of the following materials: polytetrafluoroethylene, PTFE; Polyethylene, PE, in particular ultra high molecular weight polyethylene, UHMWPE; polyetherketone, PEEK; a thermoplastic; a thermoset; polyethylene terephthalate, PET; polyoxymethylene, POM; polystyrene, PS; an insulating mineral material.
  • each of the segments can be set in one of the at least four following positions: remote (86x) or electrically isolated, a low position (861), a middle position (86m), a high position (86h).
  • Method for producing a particle foam part from foam particles comprising: a. Introducing the particles into a mold space (14) of a mold (3) which is formed from at least two mold halves (12, 13) which delimit the mold space, wherein at least two capacitor plates (15, 16) are positioned adjacent to the mold space, at least one of the capacitor plates being connected to a radiation source, and at least one of the capacitor plates having a plurality of segments (86) having an adjustable distance (d) from the mold space; b. irradiating the mold space with electromagnetic radiation emitted from the capacitor plates; and c. locally adjusting a field strength distribution of the incident electromagnetic field within the mold space by changing the adjustable distance of the segments from the mold space.
  • foam particles comprise one or more of the following base materials: thermoplastic polyurethane (TPU), polylactate
  • PHA Polyamide
  • PA Polyetherblockamide
  • PET Polyethylene Terephthalate
  • PBT Polybutylene Terephthalate
  • TPEE Thermoplastic Polyester Ether Elastomer

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  • Physics & Mathematics (AREA)
  • Health & Medical Sciences (AREA)
  • Electromagnetism (AREA)
  • Toxicology (AREA)
  • Oral & Maxillofacial Surgery (AREA)
  • Thermal Sciences (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

Dispositif (1) de production d'une pièce en mousse de particules à l'aide d'un rayonnement électromagnétique comprenant un moule (3), qui délimite une cavité (14), qui est disposée entre deux plaques de condensateur (15, 16). Au moins l'une des plaques de condensateur (15, 16) est formée de multiples segments (85, 86), et ainsi la surface de la plaque de condensateur (15, 16) peut être adaptée à la taille du moule (3). Afin de produire les pièces en mousse de particules, un rayonnement électromagnétique est utilisé pour fusionner ensemble les particules de mousse entre les plaques de condensateur (15, 16), les segments (85, 86) étant combinés. Un ensemble plaque-condensateur (90) comprend des segments (85, 86) de plaque-condensateur, qui sont conçus afin de former conjointement une plaque de condensateur (15, 16).
EP22725199.8A 2021-04-28 2022-04-22 Dispositif, procédé et ensemble plaque-condensateur pour produire une pièce en mousse de particules Pending EP4330004A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102021110841.1A DE102021110841A1 (de) 2021-04-28 2021-04-28 Vorrichtung, Verfahren und Kondensatorplatten-Set zur Herstellung eines Partikelschaumstoffteils
PCT/EP2022/060751 WO2022229030A1 (fr) 2021-04-28 2022-04-22 Dispositif, procédé et ensemble plaque-condensateur pour produire une pièce en mousse de particules

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EP4330004A1 true EP4330004A1 (fr) 2024-03-06

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EP (1) EP4330004A1 (fr)
DE (1) DE102021110841A1 (fr)
WO (1) WO2022229030A1 (fr)

Family Cites Families (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3242238A (en) 1961-04-12 1966-03-22 Edwin A Edberg Method for making foamed polymeric structural materials
US3079723A (en) 1961-10-27 1963-03-05 Carl W Roes Fishing lure
CA1011070A (en) 1972-05-30 1977-05-31 Richard H. Immel Method for bonding expanded polymeric parts
US5082436A (en) * 1989-07-14 1992-01-21 General Electric Company Apparatus for deforming thermoplastic material using RF heating
US5973308A (en) * 1997-08-05 1999-10-26 Rockwell Science Center, Inc. Efficient dielectric heater
DE10009665C1 (de) 2000-02-29 2002-01-24 Fraunhofer Ges Forschung Verfahren und Vorrichtung zum thermischen Verbinden von Polymerschaumpartikeln
DE102012008536B4 (de) 2011-10-06 2023-06-15 Gb Boucherie Nv Verfahren zum Herstellen von Bürsten sowie Bürste
DE102016100690A1 (de) 2016-01-18 2017-07-20 Kurtz Gmbh Verfahren und Vorrichtung zur Herstellung eines Partikelschaumstoffteils
DE102016123214A1 (de) 2016-12-01 2018-06-07 Kurtz Gmbh Vorrichtung zur Herstellung eines Partikelschaumstoffteils
DE102019215845B4 (de) * 2019-10-15 2023-05-11 Adidas Ag Verfahren zur Herstellung von geschäumten Partikelteilen, insbesondere für die Herstellung von Schuhsohlen
DE102019127680A1 (de) 2019-10-15 2021-04-15 Kurtz Gmbh Werkzeug, Werkzeugsystem und Verfahren zum Herstellen von Partikelschaumstoffteilen

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