JP5596413B2 - Method for producing composite or hybrid structure - Google Patents

Description

  The present invention relates to a method for producing a composite or hybrid structure containing at least one thermoplastic component.

  Conventionally, various methods are known for manufacturing a composite structure or a composite material and for manufacturing a hybrid structure. In composite materials, various materials are joined by adhesive bonding, shape fastening bonding, or a combination of both. What should be emphasized is, for example, a fiber composite material in which a textile fabric or knitted fabric is mixed with plastic, which is to obtain a composite structure with improved properties as a final effect. . In hybrid structures, systems with different technologies are combined. Very common are plastic / metal hybrids that combine the advantages of plastic and metal materials.

  Conventionally known methods for producing composite or hybrid structures are generally performed in multiple steps. For this reason, both cost and labor are high.

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  The object of the present invention is to provide a method of the kind mentioned in the introduction (technical field) (method for producing a composite or hybrid structure containing at least one thermoplastic component), which reduces labor and costs. There is.

  The object of the present invention is a method for producing a composite or hybrid structure containing at least one thermoplastic component, characterized in that it uses an injection molding machine having at least one redirecting plate. Achieved.

  By adopting an injection molding machine having at least one direction changing plate, a plurality of processes can be combined in the injection molding machine, and as a result, various processes can be combined quickly on the spot.

  In a variation of an embodiment, two molded parts are injection molded through the first and second injection stations using an injection molding machine having at least two turning plates and at least three injection stations. The molded parts can face each other after rotating the redirecting plate and can be joined to each other through the third injection station. By using two turning plates and three injection stations, not only can each molded part be produced quickly, but they can also be joined together in a continuous sequence. Here, an insertion part, preferably a functional member and / or a reinforcing structure, can be pre-placed in one of the injection stations. In this case, preferably the insertion part, preferably the functional member and / or the reinforcing structure, is placed between the two molded parts after rotation of the redirecting plate and before the joining of the two molded parts. To.

  From an economic point of view, it is advantageous that a new molded part is injected in the first and second injection stations after the turning plate has been rotated and preferably simultaneously with the joining of the already injected molded parts. This is the case where it is molded.

  In another embodiment variant, an injection molding machine having at least one turning plate and at least one injection station is used to provide a mold separation surface between the turning plate and the further mold clamping plate. A reinforcement structure (for example, a reinforcement structure consisting of a fiber ply, a fiber fabric, a prepreg or a combination thereof) is inserted, and after the turning plate has been rotated, an injection molding takes place on the reinforcement structure in the injection station. It can be made to be. In this case, the reinforcing structure can be further preformed in an injection molding machine before being injected thereon. Additionally or alternatively, the reinforcing structure can be preheated in an injection molding machine before being injected thereon.

  In a further configuration of the invention, the injection molding can be carried out on both sides of the reinforced structure by using a further injection station or by rotating the turning plate.

  In an embodiment variant, the insert can be punched out by combining the redirecting plate and the further mold clamping plate and / or punching tool in an injection molding machine. This type of punching process can be carried out by means of a mold tool or a part of the mold tool or additionally provided with a punching tool. This type of punching tool may be integrated into a part of the mold tool, so that the punching tool and the mold tool perform the punching process jointly.

  In a further embodiment variant, the reinforced structure on the film substrate can be placed in an injection molding machine.

  In all embodiment variants, the injection molding machine has two mold separation surfaces, in which one of the mold separation surfaces is preferably preformed via hydraulic pressure. In another mold separation surface, plastic can be injection-molded on the structural member.

  Furthermore, the injection molding machine has at least one direction change plate with two mold separation surfaces, where each mold separation surface is assigned an extruder and a screw injection unit, and as a result The production of composite and / or hybrid structures can be carried out by direct synthesis.

  Furthermore, the injection molding machine can have at least one rotating cube with four stations that are offset by 90 °. Two of the stations can be formed as injection stations. In one station, the insertion part can be supplied by the operating device. In one station, one station may be formed as a pick-up station or a drop station. In a further embodiment variant, the production of the composite or hybrid structure is carried out by at least partially in-situ polymerization of at least one monomer in the cavity of the injection molding machine, where By making the cavity small, pressure can be applied in the cavity. Furthermore, the production of the composite or hybrid structure can be carried out at least in part by applying a lacquer layer. As an in situ polymer and / or lacquer layer to be applied, for example, PUR (polyurethane) has proven advantageous.

  The molded part produced in the intermediate process is preferably a half shell.

  It has been found to be generally advantageous when the reinforcing structure (53) is selected from the group consisting of a fiber ply, a fiber fabric, a prepreg, or a combination thereof. Here, more advantageously, the fibers of the fiber ply and / or fiber fabric are selected from the group consisting of glass fibers, basalt fibers, carbon fibers or mixtures thereof.

  Further details and advantages of the invention will be explained on the basis of the following drawings and the description relating to the drawings.

It is a figure which shows an example of the injection molding machine for enforcing the method of this invention. Fig. 2a (Fig. 2a) shows a variation of the embodiment for carrying out the method using two redirecting plates, and Fig. 2b (Fig. 2b) shows the resulting composite structure or hybrid. It is a figure which shows a structure. Fig. 3a (Fig. 3a) is a diagram showing a modification of the embodiment for carrying out the present method by using one direction change plate and performing preforming, and Fig. 3b (Fig. 3b) shows the result. FIG. 3 is a diagram showing a composite and hybrid structure produced as follows. It is a figure which shows the modification of embodiment for implementing this method using one direction change board, and the reinforcement | strengthening structure is heated previously in this case. FIG. 5 shows two method steps for carrying out the method using one direction change plate and one punching tool. It is a figure which shows two method steps of the modification of embodiment for implementing this method using one direction change board and two injection units arrange | positioned at L-shape. It is a figure which shows two method steps of the modification of embodiment for implementing this method using one direction change board and two injection units arrange | positioned at L-shape. Fig. 7a (Fig. 7a) is a diagram showing a modification of the embodiment for carrying out the method using two direction change plates and one punching tool, and Fig. 7b (Fig. 7b) shows the result. FIG. 3 is a diagram showing a composite and hybrid structure produced as follows. Fig. 8a (Fig. 8a) is a view showing a modification of the embodiment for carrying out the present method using one direction change plate, and at this time, preforming is performed by hydraulic pressure. FIG. 8b (FIG. 8b) shows the resulting composite and hybrid structure. Fig. 9a (Fig. 9a) is a diagram showing a modification of the embodiment for carrying out the method of the present invention using one direction change plate and a plurality of twin screw extruders, and Fig. 9b (Fig. 9a). FIG. 9b) shows the resulting composite or hybrid structure. It is a figure which shows the modification of embodiment for implementing this method using a rotating cube. Fig. 11a (Fig. 11a) is a diagram showing a modification of the last embodiment for carrying out the method of the present invention using one direction change plate and a monomer supply device, and Fig. 11b (Fig. 11b). FIG. 3 shows the resulting composite or hybrid structure.

  FIG. 1 shows an injection molding machine 1 that can be used for the method of the invention. This injection molding machine 1 has a closing unit 2 and a plasticizing and injection unit 3 as is known. The closing unit 2 has a fixed mold clamping plate 4 which is fixedly arranged on a frame 9. Furthermore, a movable mold clamping plate 5 is provided, which can move linearly along the column 10 on, for example, the slide shoe 7 on the slide rail 31 shown in FIG. The movable clamping plate 5 is moved by moving the moving cylinder 16 including the piston cylinder unit in a direction away from and toward the movable clamping plate 4. In order to fix the movable mold clamping plate 5 at a desired position of the column 10, a lock mechanism 14 is provided, and the lock mechanism 14 is formed by a shape fastening coupling and / or a friction coupling, and the mold clamping plate 5. Is fixed to the pillar 10. Furthermore, a direction change plate 6 is provided, which can move on the slide shoe 8 in a straight line between the movable mold clamping plate 5 and the fixed mold clamping plate 4. The direction change plate 6 is disposed on the slide shoe 8 in the slide rail 31. Further, a moving cylinder 16 having a piston cylinder unit is provided to move linearly along the pillar 10 in a direction away from and toward the fixed fastening plate 4. The direction change plate 6 further includes a rotation unit 61 such as a rotating disk, for example, and can rotate along the rotation axis a. The mold clamping plates 4 and 5 and the direction changing plate 6 are disposed on the frame 9. Further, a pressure pad 13 is provided to support the fixed mold clamping plate 4. The closing unit 2 has mold separation surfaces A and B.

  Since the plasticizing and injection unit 3 is also constructed in a manner known per se, only a brief description will be given here. Through the filling hopper 17, the plastic particulate material can be conveyed into the plasticizing cylinder 18, in which a plasticizing screw is arranged, which plasticizes the plastic particulate material. Via the nozzle 23 and the injection movement, plasticized plastic can be injected into the mold 11. For plasticization and subsequent injection, a drive unit 24 is provided, which causes the plasticizing screw to rotate on the one hand and linearly on the other hand for injection. As is well known, the drive unit 24 can be formed with fluid pressure, for example. The plasticizing and injection unit 3 is arranged on the frame 19. The movable mold clamping plate 5 is further provided with another plasticizing and injection unit 20. The unit 20 is disposed on the frame 22, and this unit is connected to the fixed mold clamping plate 4. When the movable mold clamping plate 5 moves away from or in the direction away from the fixed mold clamping plate 4, the injection unit 20 moves with it. The injection unit 20 also has a filling hopper 21 for plastic particulate material and a plasticizing unit 25, which simultaneously form an injection unit. Plasticized plastic can be injected into the mold 12 via the nozzle 26.

  In the illustrated embodiment, two mold tools 11, 12 are recognizable, which are respectively two mold holders 11 ′, 11 ″ or mold holders 12 ′, 12 ″. It is formed by. By moving the movable mold clamping plate 5 and the direction change plate 6 along the column 10 in the direction of (or away from) the fixed mold clamping plate 4, each tool holding portion 11 ′ · 11 ″ or tool holders 12 ′, 12 ″ are closed, which form a mold space into which the thermoplastic component is injected in a plasticized state. At this time, first, injection is performed in the first closed mold tool 11, and then, after the mold tool 12 is opened, the direction change plate 6 rotates 180 ° around the rotation axis a. As a result, the mold holding part 11 ″ reaches the position where the mold holding part 12 ′ previously existed in the drawing plane. When the mold tool is closed, the mold holding part 11 ″ and the mold holding part 12 ″ overlap each other to form a new mold. At this time, the mold holding part is formed in the first period. The formed molded part remains in the mold holding part 11 ″ and is placed in a new mold. Following this, additional thermoplastic components can be injected through the injection unit 20, thereby forming a finished composite or hybrid structure 50. Furthermore, an insert can be placed in one of the two molds 11 and 12 before one of the two injection processes. Of course, it is also possible to inject into the molds 11 and 12 simultaneously. In this case, the molded part can be injected at the same time after the direction change plate 6 is rotated. The plasticizing and injection unit 3 and the mold 11 here form an injection station, and the plasticizing and injection unit 20 together with the mold tool 12 forms a further injection station.

  FIG. 2a shows a variant of the embodiment substantially corresponding to the example of FIG. 1, but in this case, on the closed side 2, in addition to the stationary mold clamping plate 4 and the movable mold clamping plate 5, The first direction change plate 6 and the second direction change plate 6 ′ are arranged so as to move linearly on the slide rail 31. In the modification of this embodiment, three mold separation surfaces A, B, and C are provided. In addition, a third plasticizing and injection unit 30 is provided, which is arranged in an approximately L-shape with respect to the first plasticizing and injection unit 3 or the second plasticizing and injection unit 20. At this time, the plasticizing and injection unit 30 is arranged on the direction change plate 6 and moves together with the direction change plate 6. The description of the remaining parts in the closing unit 2 and the plasticizing and injection units 3, 20 and 30 is omitted so that the whole can be seen well.

  Here, it should be noted that the reference numerals are the same in all the figures, and accordingly, in each figure, the description of each reference numeral is omitted. Refer to the description in the previous drawings, respectively.

  In the first method step, the mold tools 11, 12, 121 (formed by the mold holders 11 ′, 11 ″, 12 ′, 12 ″, 121 ′, 121 ″) are closed, The mold clamping plates 4 and 5 and the direction change plates 6 and 6 ′ are moved relative to each other so as to form a desired mold. On the mold tool 11 side, the plasticized thermoplastic component is injected via the plasticizing and injection unit 3, so that a molded part 51 (see FIG. 2 b) in the form of a half-shell is subsequently formed. Is done. At the same time, in the mold tool 12, a molded part 52 is formed via the injection unit 20. After removing the molded parts 51, 52 from the mold, the respective mold tools 11, 12, 121 are opened by moving the respective mold plates 5, 6, 6 'away from each other, The mold part 52 remains on the mold holding part 12 ″ and on the mold holding part 11 ″. Subsequently, the direction change plates 6 and 6 ′ are rotated by 180 ° along the rotation axes a and b. As a result, the mold holding portions 12 ′ and 11 ″ face each other in the central region. Via the operating instrument 60, the insertion part 53 can be inserted into the newly created mold. Subsequently, each mold tool is closed again, and the plastic is passed through the pipe 31 through the injection unit 30 fixed to the direction change plate 6, and the plastic becomes the new mold (mold holders 11 ″ and 12 ′. As a result, the molded parts 51 and 52 are joined to each other. At the same time, the insertion part 53 is coupled to the molded parts 51 and 52. In the illustrated case, the insertion portion 53 is considered to be a functional element (for example, an antenna, but a transponder, RFID, etc.). By opening the mold tool, the completed composite or hybrid structure 50 can be taken out.

  In FIG. 3a, the mold 12 simultaneously forms a preforming unit, applies pressure to the insertion portion 53 inserted by the operating instrument 60, and optionally raises the temperature, thereby preliminarily forming the preform. 56 is preformed. After the mold tool is opened and the direction changing plate 6 is rotated around the rotation axis a, the preformed portion left in the mold holding part 12 ′ can be inserted into the newly formed mold. Subsequently, the thermoplastic component exiting the plasticizing and injection unit 3 can be injected onto this molded part.

  FIG. 4 shows a variant of the embodiment with only one direction change plate 6 and only one plasticizing and injection unit 3. In the opened state, the insertion portion 53 is placed in the mold 12 at a position in contact with the mold holding portion 12 ″ through the operation instrument 60. The mold tool 12 has a heating device 70 that heats the insertion portion 53 in advance. The insert 53 is preferably a so-called prepreg (often also referred to as Organoblech (German)), which is preferably a fiber reinforced plastic, for example a fiber reinforced thermoplastic. Accordingly, the insertion portion 53 forms a reinforced structure. Specifically, the insertion portion 53 is a prepreg having glass fiber reinforced plastic, and is inserted into the mold 12 and heated by the heating device 70. As a result, the plastic is softened. Heating takes place in the closed mold tool 12. After heating in the mold tool 12 and optionally pressing the mold, the mold 12 is reopened, the direction changing plate 6 rotates, and the insertion portion 53 holds the mold in a heated state. When in the part 12 'and closed, a new mold tool is formed with the mold holding part 11'. Subsequently, the plasticized plastic is injected into the mold formed by the mold holding portions 11 ′ and 12 ′ through the injection and plasticizing unit 3, and the corresponding composite or hybrid structure 50 is generated. Is done.

  In FIG. 5, a further embodiment is shown. In this case, the material band 53 ′ is overlapped with the punching tool 71 (in contact with the protrusion 72 of the mold holding part 12 ″ so that a part of the material band 53 ′ is punched), The insertion portion 53 is inserted by punching. The punching tool 71 advances on the mold holding part 12 ″ until it comes into contact with the stopper of the protruding part. At this time, the insertion portion 53 is separated from the material strip 53 'and transferred into the mold 12'. After opening the mold, the direction change plate 6 is rotated, moved to the right position in the drawing, and the mold is closed by overlapping the mold holding portions 12 'and 11', and the resulting mold Confinement takes place in the mold tool. Finally, through the plasticizing and injection unit 3, thermoplastic components are injected into the mold to produce a finished composite or hybrid structure 50.

  FIGS. 6 a and 6 b show a variant very similar to the embodiment of FIG. 4, where the insertion part 53 is also inserted into the mold 12 via the operating tool 60. A thermoplastic component can be injected into the mold 12 from one side via a plasticizing and injection unit 30 arranged on the direction change plate 6. This is illustrated in FIG. 6b. After the mold 12 is opened and the direction change plate 6 is rotated and newly closed, it can be injected into the mold part 51 on the second side via the plasticizing and injection unit 3. The resulting composite or hybrid structure 50 is presented on the lower right side of the drawing, where the outer two plastic layers 51, 52 and the insert 53 between them can be recognized. Again, the insert can be a prepreg or other material.

  FIG. 7a shows an integrated form of the modification of the embodiment of FIGS. 5, 6a and 6b. In this case, first, the insertion portion 53 is punched from the material band 53 ′ with the punching tool 71, and the first In the mold 12. After rotating the first redirecting plate 6 ′, it can be injected into one side of the insertion part 53 via the plasticizing and injection unit 30. After the mold is newly opened, the direction change plate 6 is closed, and the mold is closed, injection is performed around the second side of the insertion portion 53 via the plasticizing and injection unit 3.

  Figures 8a and 8b show a further embodiment variant for carrying out the method. In this case, the insertion portion 53 is inserted into the first mold through the operation instrument 60. Due to the so-called internal high pressure deformation in the mold, the mold shown on the left in FIG. 8b can be generated from the insertion part 53 via the liquid. After rotating the redirecting plate 6 and closing it again and injecting through the plasticizing and injection unit 3, the finished composite or hybrid structure 50 shown on the right in FIG. 8b can be produced.

  9a and 9b show a modification of the present invention. In this case, in addition to the plasticizing and injection unit 3 and the plasticizing and injection unit 20, biaxial screw extruders 99 and 99 ′ are further provided. ing. This allows direct synthesis. In this case, the conventional thermoplastic component is plasticized via the plasticizing and injection unit 3 and / or additionally further thermoplastic with further components via the twin screw extruder 99. The plastic component is plasticized. This component is transported into the plasticizing cylinder of the injection unit 3 and after the mold tool 11 is closed, an injection process is performed. The same applies to the injection unit 20 and the twin screw extruder 99 'assigned to it. The manufacture of the composite or hybrid structure 50 (using the insertion portion 53 if necessary) is performed in the same manner as described in FIG. Further, it is possible to provide a shot pot (not shown), whereby the biaxial screw extruders 99 and 99 'can be plasticized even when the injection units 3 and 20 are used for injection.

  FIG. 10 shows a modification of the embodiment using a rotating cube 6, in which case the axis of rotation a is horizontal, i.e. perpendicular to the drawing, and this rotating cube 6 has four positions or Stations I, II, III and IV are separated from each other by 90 °. The rotation axis a may be arranged vertically as in the above example. The presentation shown in FIG. 10 is selected to give a good overview, and each station I / II / III / IV looks better. The first station I shows the injection process of the first molded part having a half-shell shape. After opening the mold, the direction changing plate is rotated by 90 °, and the insertion portion 53 is placed in the mold holding portion 11 ′ via the operation tool 60 (station II). After 90 ° rotation again (station III), the mold is closed again and the thermoplastic component is injected through the plasticizing and injection unit 20. After the mold is reopened and the turning plate or rotating cube is rotated 90 °, the completed composite or hybrid structure 50 is removed via the removal station (station IV). This is also the dropping station.

  The variant of the embodiment of FIGS. 11a and 11b differs from the embodiment of FIG. 1 only in that in addition to the plasticizing and injection unit 20, a unit 93 is also provided for inserting plastic to be polymerized. . In this case, at least one monomer is first placed in the cavity and polymerized in this cavity. At the start of polymerization, high pressure is applied to the cavity by making the cavity smaller. Thus, for example, a thin lacquer layer 52 (eg PUR lacquer) can be applied. Alternatively, thermoplastic components can be introduced via the plasticizing and injection unit 20. Preferably, the thermoplastic component can be applied as a thin layer, for example by injection molding.

  With the exception of FIG. 10, in the embodiment, the rotation axes a and b of the direction change plates 6 and 6 ′ can be arranged horizontally (similar to FIG. 10) instead of vertically.

4 Fixed mold clamping plate 5 Movable mold clamping plate 6, 6 'direction changing plate 50 Composite or hybrid structure 51, 52 Molded part 53 Insertion part (preferably functional member and / or reinforced structure)
60 Operating device 71 Punching tool 99, 99 'Extruder A, B, C Mold separation surface

Claims (10)

A method for producing a composite or hybrid structure (50) containing at least one thermoplastic component, comprising:
The method uses an injection molding machine (1) having at least one turning plate (6),
The injection molding machine (1) further includes
A first mold tool (11) comprising two mold holding parts (11 ′, 11 ″) divided by a first mold separation surface (A), the two mold holding parts A first mold tool, one of which is supported on said turning plate (6);
A second mold tool (12) comprising two mold holders (12 ', 12'') divided by a second mold separation surface (B), the two mold holders A second mold tool, one of which is supported on said direction change plate (6);
With
The method further uses an insertion portion (53) selected from the group consisting of a fiber ply, a fiber fabric, a prepreg, and combinations thereof as a structural member,
The fibers of the fiber ply and the fiber fabric are selected from the group consisting of glass fibers, basalt fibers, carbon fibers, natural fibers, and mixtures thereof,
At one position of the first and second mold separation surfaces (A, B), an insertion portion (53) as a structural member is preformed by applying pressure, and the first and second mold separating surfaces (A, B) are preliminarily molded. At the other position of the two mold separation surfaces (A, B), plastic is injection-molded onto the insert part (53) as a pre-formed structure member, and as a result, the pre-formed insert part. (53) A composite or hybrid structure (50) in which plastic is integrated is obtained . The injection molding machine (1) has two direction change plates (6, 6 ') and three injection stations,
An insert (53) is provided in one of the three injection stations;
Through the first and second injection stations, two molded parts (51, 52) are injection-molded, these molded parts face each other after rotating the direction change plate (6, 6 '), the third injection station The method of claim 1, wherein the methods are coupled together. The injection molding machine (1) has a mold clamping plate (4, 5) and an injection station in addition to the at least one direction changing plate (6, 6 ′),
An insertion member (53) as a reinforcing structure is provided at the position of the mold separation surface (A, B, C) between the direction changing plate (6, 6 ') and the mold clamping plate (4, 5). Inserted,
The method according to claim 1, characterized in that after the turning plate (6, 6 '), an injection molding is performed on the reinforcing structure (53) in the injection station.   4. A method according to claim 3, characterized in that the reinforcing structure (53) is preformed in the injection molding machine before being injection molded onto it.   The method according to claim 3 or 4, characterized in that the reinforcing structure (53) is preheated in the injection molding machine (1) before being injection molded onto it.   4. Injection molding on both sides of the reinforcing structure (53) by using a further injection station or by rotating the direction change plate (6, 6 '). The method as described in any one of -5. The injection molding machine (1) further includes a punching tool (71) for punching the insertion portion (53) from the material band (53 ′), and the insertion portion (53) is punched by the punching tool (71). ) Is placed in an injection molding machine (1),
A method according to any one of claims 1-6.   The injection molding machine (1) further comprises an extruder (99, 99 ') assigned to each mold separation surface (A, B, C) and a screw injection unit, resulting in a composite or hybrid structure. 8. Process according to any one of the preceding claims, characterized in that the production of the body (50) is carried out by direct synthesis. The direction change plate is constituted by a rotating cube (6) with four stations (I, II, III, IV) arranged 90 ° apart from each other,
Two of the four stations are configured as injection stations,
One of the four stations is configured as a pick-up station or drop-off station;
The insertion portion (53) can be supplied by the operating device (60) in one of the four stations.
The method according to claim 1. 10. A method according to any one of the preceding claims , characterized in that the production of the composite or hybrid structure (50) is carried out at least partly by applying a lacquer layer.

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