TWI606910B - Pmi發泡體之新穎成形方法 - Google Patents
Pmi發泡體之新穎成形方法 Download PDFInfo
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- TWI606910B TWI606910B TW102125941A TW102125941A TWI606910B TW I606910 B TWI606910 B TW I606910B TW 102125941 A TW102125941 A TW 102125941A TW 102125941 A TW102125941 A TW 102125941A TW I606910 B TWI606910 B TW I606910B
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- Taiwan
- Prior art keywords
- forming
- foam
- tool
- heating
- foamed material
- Prior art date
Links
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Classifications
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Description
本發明關於例如可用於製造具有由剛性發泡體所構成之核心的複合材料之新穎方法。本發明在這方面具有可自由選擇發泡體材料及外層二者的相當顯著優點。尤其是,本方法可處理其加工溫度與該核心材料之加工溫度截然不同的外層。
本發明另外關於一種方法,藉由該方法在一第二具體實例中,可將整體發泡之結構部分固結。在一第三具體實例中,二或多個已發泡材料之工件可融合在一起,產生具有特別高級接合的中空物件。此可在具有或不具有外層的情況下完成。
此外,本發明非常適用於藉由真空成形來加工發泡體材料。
各種用於製造包含剛性發泡體之纖維強化塑膠或用於
使剛性發泡體成形的方法係籠統描述於先前技術中。本發明內容中之剛性發泡體係不像市售PU或聚苯乙烯發泡體,例如其不會因最小力而可機械性變形然後回復。剛性發泡體之實例尤其是PP、PMMA或高度交聯PU發泡體。聚(甲基)丙烯醯亞胺(PMI)(例如由Evonik以商品名Rohacell®銷售者)為特別堅固之剛性發泡體。
為人熟知之用於製造所述複合材料的方法係形成外層,然後引入發泡體原料,最終使該發泡體原料發泡。此種方法描述於例如US 4,933,131中。該方法的一項缺點係該發泡體經常非常不均勻。此在諸如PMI之材料中特別明顯,其最多只能作為顆粒添加。該方法的另一缺點係外層將必須再次移除,以形成構造之純發泡體材料。在複合結構組件之情況下,介於外層與發泡體核心之間的附著力反而經常不足以用於受機械性應力之結構組件。
在Passaro等人之Polymer Composites(25(3),2004,第307頁之後)描述一種方法,該方法中PP發泡體核心材料係在壓縮模中接合至纖維強化塑膠,該壓縮模特別只有在加熱該發泡體核心材料之表面以使得可獲致與外層材料的良好結合。在Grefenstein等人之International SAMPE Symposium and Exhibition(35(1,Adv.Materials:Challenge Next Decade),1990,第234-44頁)中,描述用於製造具有蜂巢核心材料或PMI發泡體核心之夾層材料的類似方法。然而,採用這兩種方法均不可能成形,只製造呈片材形式之夾層材料。
WO 02/098637描述一種方法,該方法中熱塑性外層材料係呈熔體方式施加至發泡體核心材料之表面,然後以雙片程序(twin sheet pzocess)與該發泡體核心模塑在一起,以形成複合模塑物,然後使該熱塑性塑膠冷卻以使外層材料在該模中硬化。然而,只有有限數量之材料可使用此方法結合。例如,無法獲得纖維強化外層材料。該方法亦不能用以純粹形成無外層材料的發泡體工件。此外,發泡體材料的選擇受限於在低溫下可彈性成形的材料。剛性發泡體在此種發泡體材料不均勻加熱的方法中會遭受過多結構損壞。
EP 0 272 359中所描述的方法非常相似。先將發泡體核心預成形物裁切成形並置於模中。然後,將熱塑性材料之熔體注入表面。接著升高溫度以使該發泡體核心預成形物膨脹,致使擠壓至外層材料的表面。該方法確使提供對於外層材料的較佳附著力,但由於初始成形之額外步驟而使成本更高及不便,因此整體來說在可實現形狀方面明顯更受限。
在W.Pip之Kunststoffe(78(3),1988,第201-5頁)中描述一種用於在壓縮模中製造具有纖維強化外層及PMI發泡體核心的成形複合物之方法。該方法中,個別層係在已加熱之壓縮模中接合在一起,同時以在被壓縮之局部受熱發泡體材料中的最上層進行稍微成形。又描述一種可藉由在該模中二次成形來製造的形狀之方法。此種方式的缺點係如上述討論。作為第三種變體,揭示一種在壓縮
模塑已預熱之發泡體材料時對材料進行彈性壓縮的方法。在爐中完成預熱。然而,該方法的缺點在於許多發泡體材料需要非常高溫以熱塑成形。例如PMI發泡體需要至少185℃之溫度。另外,核心材料整體必須已經適當加熱以避免材料失效。然而,在此等溫度下,尤其因若欲使該等溫度均勻分布,只有延長加熱數分鐘才可能,故許多外層材料(諸如PP)會嚴重損壞,因此無法進行該方法。
在U.Breuer之Polymer Composites(1998,19(3),第275-9頁)中揭示用於PMI發泡體核心之Pip的第三種變體之稍微修改方法。該PMI發泡體核心及纖維強化外層材料係使用IR加熱燈加熱。此種發出尤其是介於3與50μm之範圍中的波長之光(IR-C或MIR輻射)的IR加熱輻射器特別適用於快速加熱基板。然而,所需要的能量輸出非常高,因此同時造成許多外層材料(諸如PP)的損壞。因此,Breuer等人之論文中只揭示聚醯胺12(PA12)作為可能用於外層的基質材料。PA12容易加熱至高於200℃而且該塑膠不會受損。同時該操作方法中不可能使發泡體核心成形,原因係此IR光譜之熱輻射不會穿透至該發泡體基質中,因此不會獲得可熱塑性成形的狀態。
在所討論先前技術背景之下,本發明的目的因而係為
提供一種新穎方法,藉由該方法可迅速並簡單地使剛性已發泡材料成形而無結構損壞,及/或可與外層(尤其是與熱塑性材料)一起加工成複合物。
本發明更特別的目的是提供一種以成形操作製造複合材料,同時表面材料之選擇相對自由而且在加工期間表面材料不受損的方法。
另外,該方法應適用於具有或不具有外層材料之部分固結的已發泡材料。該方法亦應適於由二或多種具有或不具有外層的材料製造中空物件。此外,該方法應可修改以使得可與真空成形操作結合。
此外,與所提出作為目的之個別具體實例無關,該新穎方法應容許明顯少於10分鐘的快速循環時間。
此處未明確討論之其他目的可在下文由先前技術、說明、申請專利範圍或範例具體實例而明暸。
該等目的係藉由用於形成已發泡材料的新穎方法獲致。該新穎方法尤其適於使高度交聯之聚胺基甲酸酯(PU)、聚丙烯(PP)的剛性發泡體,或聚(甲基)丙烯醯亞胺(尤其是聚甲基丙烯醯胺(PMI))之剛性發泡體成形。該方法包括以下步驟:a)隨意地以外層材料及在其間之發泡體核心複合層疊層,b)藉由以波長介於0.78與1.40μm之間的近紅外
線輻射(NIR輻射)的照射來加熱該已發泡材料,c)以成形工具成形,d)將最終工件冷卻及脫模。
在這方面可能有兩種不同具體實例。第一具體實例中,用於以NIR輻射加熱的工具及成形工具係彼此分開。
此情況下之方法包括以下步驟:a)隨意地以外層材料及在其間之發泡體核心複合層疊層,b1)導入加熱場之機械側活性區中,b2)藉由以波長介於0.78與1.40μm之間的近紅外線輻射(NIR輻射)的照射來加熱該已發泡材料,c1)將該已發泡材料轉移至成形工具中,c2)以該工具成形,及d)將該最終工件冷卻及脫模。
在第二具體實例中,該用於以NIR輻射照射之加熱裝置為該成形工具的整體組件:a)隨意地以外層材料及在其間之發泡體核心複合層疊層,b1)導入配備有可移除之加熱場的成形工具中,b2)藉由以波長介於0.78與1.40μm之間的近紅外線輻射(NIR輻射)的照射來加熱該已發泡材料,
c1)從該成形工具之操作範圍移除熱,c2)以該工具成形,及d)將該最終工件冷卻及脫模。
方法步驟b1)及b2)應理解為上述具體實例中之方法步驟b)的附屬步驟。方法步驟c1)及c2)相對於方法步驟c)而言亦然。
令人意外的,已發現方法步驟b)中之材料的溫和加熱(或該實例可為b2))因均勻熱輸出而引發可塑性成形性同時該材料未遭受任何損壞。尤其是,適當實施本方法時,不會發生例如在烘箱中加熱時所觀察到之剛性發泡體表面損壞。因所使用之NIR光譜產生的熱輻射通過該發泡體孔室中之氣相而不被吸收,並完成該孔室壁基質的直接加熱。
在本發明方法的特別具體實例中,步驟d)中的成形係在減壓(例如,在真空中)使用雙片程序進行。所使用之雙片程序裝備係經組態以使其可用作壓縮模塑機。
該雙片程序的原理為二或多個工件係在一個方法步驟中於真空(即,在減壓下)成形,同時在無添加劑(諸如黏著劑、熔接助劑或溶劑)情況下融合在一起。該方法步驟可以高循環時間,以經濟且環保的方式進行。本發明人意外地發現,藉由包括在步驟b)中以波長介於0.78與1.40μm之間的NIR輻射照射來預熱工件的額外步驟,該方法亦可用於加工根據先前技術之判斷顯示出不適於此種加工的上述剛性發泡體。以所提及之輻射相對快速加熱使
熱無應力並均勻遍布該工件。且該輻射可視所使用之已發泡材料而定,在所述範圍內改變強度。當另外使用外層材料時,加熱場之溫度及其強度係經修改,以使得即使在不同加工及成形溫度下,發泡體核心及外層材料共同成形並結合在一起。此等修改係由熟悉本技術之人士以個別實驗進行。
根據本發明方法的一個極佳優點係可以環保方式且非常高循環時間進行,同時在一個操作中結合複數個步驟。
且原理新穎之本方法產生各可用以產生完全新穎產物的全系列變體:在第一變體中,成形步驟d)提供該已發泡材料之局部固結。藉由此種局部固結可製成新穎產物。包含具有局部固結之剛性發泡體的剛性發泡體之成形物件用途更多而且整體更安定。亦可獲致新穎形狀。此產物亦有利的原因係可在已固結區域特別引入強化物、插件或螺旋聯結器,以確保從技術周邊諧調引入力。此種插件或螺旋聯結器使該已發泡材料隨後在運輸工具或航空構造中容易進一步加工。此等區域亦經常完成更佳黏附或熔接結合。本發明之方法的此變體對於例如PMI發泡體可以少於5分鐘之循環時間進行。此變體特別令人意外的是,根據先前技術判斷,此種結構組件無法以單一步驟方法製造。
在本發明方法的第二修改中,步驟d)包含雙片程序。
當已發泡材料係在步驟a)中以外層材料覆蓋在一面
或雙面,因此該雙片程序提供具有一面或雙面外層與剛性發泡體核心時,根據本發明方法之此變體特別佳。該第二變體可以少於6分鐘之循環時間進行。
令人意外的,外層材料之選擇相對自由。吾人可選擇例如純熱塑性塑膠、其梭織物或針織物或複合物,例如所謂有機板(organopanel)或有機片(organosheet),或塗層塑膠之紡織品底布,諸如人造皮革。外層材料較佳包含纖維強化塑膠。該等纖維繼而可為例如芳族聚醯胺、玻璃、碳、聚合型或紡織品纖維。該塑膠繼而較佳可包含PP、聚乙烯(PE)、聚碳酸酯(PC)、聚氯乙烯(PVC)、環氧樹脂、異氰酸酯樹脂、丙烯酸酯樹脂、聚酯或聚醯胺。
該方法的第三種變體中,最初在步驟a)中裝填已發泡材料之二或多個獨立件,然後在步驟d)之成形中從該等獨立件模塑中空物件。該變體變可經設計以使得獲得具有多於一個空隙的成形件。該變體之優點在於在無黏著劑或隨後熱熔接的情況下可獲得此類型之中空物件。此繼而具有所得中空物件具有之安定與重量的組合優於先前技術之中空物件的益處。此外,該中空物件具有較佳外觀。此甚至可延伸至在最終產物中幾乎看不到兩個原始已發泡材料之間的接合(若存在接合的話)。更特別的是,該方法中形成的縫隙幾乎無法與周圍材料區分(若存在縫隙的話),並且可保存此接合以及其他處的孔結構。該方法亦可採用雙片程序形式。在此情況下,即使非常複雜的幾何
形狀亦可在少於5分鐘之循環時間中以良好重現性實現。
在本發明之一具體實例(其與該第三變體相較有小幅修改)中,即使剛性發泡體之個別工件亦可在減壓下真空成形成非常複雜的工件。該方法尤其適用於厚度至10mm之發泡體。較佳地,步驟c)中將已發泡材料轉移至發泡工具係直接進行或者緊接在該發泡工具中以壓縮空氣預成形之後進行。
原則上,在其他修改當中,該等方法可在雙殼型工具中進行。此導致均勻較高幾何精確度。本發明之另一極佳優點係前文討論的三個變體亦可在根據本發明之一個同步進行程序中自由地彼此組合。例如,可獲得具有一或多個空隙之邊緣固結的物件。類似地,可獲得具有部分固結之已發泡核心及/或一或多個空隙的複合物。
通常,與所述之本發明具體實例無關,使用夾架使材料在該裝備中固定定位以防止任何滑動。為此目的,待加工之材料延伸超出該工具緣例如數公分,並在該區域中以所提及的夾架強迫其向下。
使用本發明方法可加工的剛性發泡體材料可由熟悉本技術之人士自由選擇。PMI為較佳剛性發泡體材料。此種PMI發泡體通常以兩步驟方法製造:a)製備鑄塑聚合物,及b)使該鑄塑聚合物膨脹。
為製備該鑄塑聚合物,第一步驟係製備包含(甲基)丙烯酸及(甲基)丙烯腈(較佳為介於2:3與3:2之莫耳比)的單體混合物作為主要成分。此外,可另外使用共
聚單體,例如丙烯酸或甲基丙烯酸之酯類、苯乙烯、順丁烯二酸或伊康酸,或其酐類,或乙烯吡咯啶酮。然而,該共聚單體部分應不超過30重量%。亦可使用少量交聯單體,例如丙烯酸烯丙酯。然而,該等數量較佳係不超過0.05重量%至2.0重量%。
該共聚混合物另外包含在約150至250℃之溫度分解或蒸發以形成氣相的發泡劑。該聚合作用係在低於此溫度進行,因此該鑄塑聚合物含有潛在發泡劑。該聚合作用合宜地呈介於兩塊玻璃板之間的厚板形式發生。
然後在第二步驟中於適當溫度下使該鑄塑聚合物膨脹。此種PMI發泡體的製造原則上已為熟悉本技術之人士知曉,且可在例如EP 1 444 293、EP 1 678 244或WO 2011/138060中回顧。特別可提及得自Evonik Industries AG之Rohacell® PMI發泡體。丙烯醯亞胺發泡體在製造及加工方面必須被視為PMI發泡體的類似物。然而,基於毒性因素,彼等明顯比其他發泡體材料不宜。
PVC發泡體為第二可加工剛性發泡體。其係從纖維複合物技術及軌道車構造之夾層製造、風力發電系統之製造,及從造船而廣為人知。發泡體之最終片材可類似PMI發泡體片材地進行加工。
在細節上做必要的修正,此亦適用於PP剛性發泡體。PP發泡體特別為人熟知的是作為絕緣材料、用於輸送貨櫃及作為夾層材料。PP發泡體可含有填料並且經常可購得密度範圍介於20至200kg/m3者。
接著,PU剛性發泡體可以較少開孔結構及較高交聯而與PU撓性發泡體區分。PU剛性發泡體可額外含有相當大量的無機填料材料。
所需之已發泡部件經由適當選擇玻璃板或經由模內成形來獲得。或者,彼等可藉由從已發泡體之膨脹片材裁切、鋸切或磨出而獲得。較佳可由一塊片材裁切二或多魂已發泡部件。
該剛性發泡體材料之密度可相對自由選擇。可使用在例如25至220kg/m3之密度範圍中的PMI發泡體。
發泡體核心之鋸切、裁切或碾磨件優於以模內成形所製造者的優點係表面具有開孔。當接觸已浸漬樹脂之纖維時,一些未完全固化之樹脂將滲透至該發泡體核心表面的該等開孔中。此具有一旦固化完成之後在發泡體核心與包覆材料之間的界面獲得特別強之附著力的優點。
原則上,本發明之剛性發泡體工件具有非常多用途。
以該具有局部固結的第一變體所獲得之工件亦可稱為具有整體結構的發泡體。此等以及在複合材料之其他變體中尤其適用於當導入力之界面與環繞(複合物)結構組件的材料之周圍結構接著時附隨的應用。此適用於其中由金屬或其他塑膠製成之結構組件係結合至該已發泡材料及/或該複合物的任何可想像的設計。此等先決條件尤其存在汽車構造、航太技術、船構造、軌道運輸工具之設計、機械工程、醫療裝置工程、家具製作、風力發電系統之建造及用於昇降機構造領域中。
即使無整體結構,該第二變體之複合材料可特別應用於大量製造,例如車體構造或汽車產業中的內裝、軌道運輸工具或船隻構造中之內部部件、在航太產業、機械工程、家具構造或風力發電系統之設計。
包含剛性發泡體之中空物件繼而可用於例如電池外殼、空調中之總氣管或作為風輪葉片之空氣動力學次組合件(例如作為尾緣)。但亦可想像在上述產業中之應用。
圖1
A‧‧‧加熱階段
B‧‧‧成形
(1)‧‧‧成形工具之頂部部分
(2)‧‧‧成形工具之底部部分
(3)‧‧‧頂部加熱器(NIR輻射器)
(4)‧‧‧底部加熱器(NIR輻射器)
(3a)及(4a)‧‧‧移除之加熱器
(5)‧‧‧發泡體核心
(6)‧‧‧夾架
(7)‧‧‧外層
圖2
A:加熱階段;B:成形
(1)‧‧‧成形工具之頂部部分
(2)‧‧‧成形工具之底部部分
(3)‧‧‧頂部加熱器(NIR輻射器)
(4)‧‧‧底部加熱器(NIR輻射器)
(3a)及(4a)‧‧‧移除之加熱器
(5)‧‧‧發泡體
(6)‧‧‧夾架
A:加熱階段;B:成形
(1)‧‧‧成形工具之頂部部分
(2)‧‧‧成形工具之底部部分
(3)‧‧‧頂部加熱器(NIR輻射器)
(4)‧‧‧底部加熱器(NIR輻射器)
(3a)及(4a)‧‧‧移除之加熱器
(5)‧‧‧發泡體(此處:頂部部分之第一工件)
(6)‧‧‧夾架
(8)‧‧‧發泡體(底部部分之第二工件)
A:加熱階段;B:成形
(2)‧‧‧成形工具之底部部分
(3)‧‧‧頂部加熱器(NIR輻射器)
(4)‧‧‧底部加熱器(NIR輻射器)
(4a)‧‧‧移除之底部加熱器
(5)‧‧‧發泡體
(6)‧‧‧夾架
(7)‧‧‧外層
(9a)‧‧‧在正壓下之機械空間
(9b)‧‧‧在負壓(真空)下之機械空間
圖1:以已發泡核心製造纖維強化塑膠,A:加熱階段;B:成形。
圖2:以部分固結之發泡體製造整體結構,A:加熱階段;B:成形。
圖3:中空物件之成形,A:加熱階段;B:成形。
圖4:發泡體之真空成形,A:加熱階段;B:成形。
茲將以籠統描述本發明之一些特別的具體實例。該等具體實例亦含有實施例。成功進行對應測試。
該方法係在雙片成形機(諸如得自Geiss AG之T8
型)上進行。該機器配備以下構造:具有閃光輻射器(NIR;0.78至1.40μm)之加熱場可調整工作空間之窗可調整高度之頂部加熱器模塑力30公噸(分鐘),馬達驅動可加熱及可冷卻成形模參考圖1以說明該具體實例。
大體上,程序參數係視個別實例中所使用的設備的布局來選擇。彼等必須在初步測試中決定。參考溫度TF取決於PMI發泡體基質之Tg(S)、外層之成形溫度、頂部加熱器之最高設定Tg(S)TF(頂部加熱器之溫度)。介於該頂部加熱器與該發泡體基質之間的距離愈大,則該頂部加熱器必須設定的溫度愈高。取決於結構組件之部分區域的可成形性(Ug),亦可改變輻射器場強度(I)。輻射器場強度I係經選擇以在靠近該夾緊裝置邊緣處接近100%,以確保該材料之持續流動,同時維持該材料之夾緊狀態。
外層之疊層:可將不同外層材料施加於該發泡體核心之一面或雙面。實例包括懸垂性織物/紗、由各種具備熱塑性相之不同纖維類型或纖維摻合物製造的複合物(及已知為有機板或有機片),或熱塑性外層,諸如PC、PMMA、PVC或其他能結合至發泡體表面之可熱塑成形的塑膠。此可隨意地使用熱熔融黏著膜或網作為黏著促進劑來完成。在特殊實例中,使用得自Bond Laminates之800
μm的有機板或有機片之厚層(Tepex® Dynalite 102-RG600)作為頂部及底部。另一實例使用雙面厚度為1500μm之Lexan聚碳酸酯片。
製程:所使用之發泡體核心為得自Evonik Industries AG之密度為51kg/m3且厚度為15mm的Rohacell® S型PMI發泡體。因鋁型膠帶或高亮度不鏽鋼板之故,該夾緊裝置較佳應在內表面上具有鏡面最後加工。外層之格式尺寸取決於窗尺寸的設定並決定為使得該等外層與該窗在長及寬方面重疊約5cm,如此可由夾架抓住。待成形之發泡體核心可與該等外層一起定位在該工作窗上方,且使該夾架降低以將其固定就位。
在加熱至210℃之PMI發泡體的成形溫度期間,可觀察到該等外層開始呈波浪形。在持續之塑化開始時,在機械空間中打入個別壓縮空氣脈衝以防止下垂至該底部加熱器上。視外層之要求而定,參考溫度及熱輻射器的強度可在約3至4分鐘之後改變以使得該等外層材料塑性變形成可懸垂狀態。然後使該參考溫度短暫地再提高約5℃以使該材料具備更大殘留熱。
在加熱階段結束時,將該底部及頂部加熱場移出該半邊工具的操作範圍,並儘可能迅速進行在介於120℃與150℃之間的溫度之溫度受控制的工具之閉合動作。以此方式,在一個操作中使該等外層沿著該工具幾何形狀成形及懸垂。在該工具冷卻至低於80℃之後,最終可移出該結構組件。在該工具加熱之後,可開始下一個複合結構組
件的製造。
該程序係在例如如實施例1所述之相同的Geiss AG之T8型雙片成形機上進行。再次,程序參數大體上係視個別實例中所使用的設備的布局來選擇。參考溫度TF類似地遵從實施例1之對應陳述。參考圖2以說明該具體實例。
製程:本實施例使用得自Evonik Industries AG之密度為110kg/m3的Rohacell® IG型PMI發泡體。該材料之初始厚度為60mm。經由該工具中之使該材料部分固結的凸出之圓錐形獲致在直徑約25mm上部分固結34mm之厚度。在約6分鐘之循環時間過程中,在該結構組件之其他區域中亦重現具有窄半徑與相當大固結程度的該工具幾何形狀。
因鋁型膠帶或高亮度不鏽鋼板之故,該夾緊裝置較佳亦應在內表面上具有鏡面最後加工。該發泡體之格式尺寸取決於窗尺寸的設定並決定為使得該發泡體格式與該窗在長及寬方面重疊約5cm,如此可由夾架抓住。待成形之發泡體格式係定位在該工作窗上方,且使該夾架降低以將其固定就位。
視部分固結程度而定,例如在待導入配件(諸如插件)的區域中,可改變該熱強度。在該特殊實施例中,存在使用閃光輻射器(NIR;0.78至1.40μm)之初始加熱
至190℃之溫度的階段。在持續之塑化最初時,在發泡體厚度15mm之下於機械空間中打入個別壓縮空氣脈衝以防止任何下垂至該底部加熱器上。在該加熱階段之後,使該參考溫度短暫地再提高約5至10℃以使該材料具備更大殘留熱。
為了成形,在加熱階段結束時,將該底部及頂部加熱場移出該半邊工具的操作範圍,並儘可能迅速進行在介於120℃與150℃之間的溫度之溫度受控制的工具之閉合動作。以此方式,在一個操作中發生該結構組件之個別區域的成形及同時發生固結。在同一操作中,可同時導入插件。
在該工具冷卻至低於80℃之後,最終可移出該結構組件。在該工具加熱之後,可開始下一個纖維-塑膠複合結構組件的製造。
該程序係在例如如實施例1所述之相同的Geiss AG之T8型雙片成形機上進行。再次,程序參數大體上係視個別實例中所使用的設備的布局來選擇。參考溫度TF類似地遵從實施例1之對應陳述。參考圖3以說明該具體實例。
製程:本實施例使用得自Evonik Industries AG之密度為110kg/m3的Rohacell® IG型PMI發泡體。在各例中,這兩個發泡體格式的初始厚度為15mm。
因鋁型膠帶或高亮度不鏽鋼板之故,該夾緊裝置較佳亦應在內表面上具有鏡面最後加工。該發泡體之格式尺寸取決於窗尺寸的設定並決定為使得該發泡體格式與該窗在長及寬方面重疊約5cm,如此可由夾架抓住。將兩個發泡體格式導入該機器的雙板框架中。該等待結合以形成中空物件之發泡體格式係定位在該工作窗上方,且使該夾架降低以將其固定就位。
根據成形程度,可改變該熱強度。在該特殊實施例中,存在使用閃光輻射器(NIR;0.78至1.40μm)之初始加熱至195℃之溫度的階段。在持續之塑化開始時,在發泡體厚度15mm之下於機械空間中打入個別壓縮空氣脈衝以防止任何下垂至該底部加熱器上。在該加熱階段之後,使該參考溫度短暫地再提高約5至10℃以使該材料具備更大殘留熱。
為了成形,在加熱階段結束時,將該底部及頂部加熱場移出該半邊工具的操作範圍,並儘可能迅速進行在介於120℃與150℃之間的溫度之溫度受控制的工具之閉合動作。藉由將該可塑性變形之發泡體板吸至該頂部及底部工具之內側壁上來進行成形。同時,有關工具幾何形狀之設計措施確保該等發泡體格式沿圓周熔接在一起。該方法中的中空物件以輪廓一致方式重現該工具幾何形狀,並使周圍邊緣熔接在一起,以使得形成無縫隙的均勻發泡體結構。
在該工具冷卻至低於80℃的溫度之後,可移出該結
構組件。在該工具加熱之後,可開始下一個纖維-塑膠複合結構組件的製造。
該程序係在例如如實施例1所述之相同的Geiss AG之T8型雙片成形機上進行。再次,程序參數大體上係視個別實例中所使用的設備的布局來選擇。參考溫度TF類似地遵從實施例1之對應陳述。參考圖4以說明該具體實例。
製程:本實施例使用得自Evonik Industries AG之密度為71kg/m3的Rohacell® HF型PMI發泡體。該成形格式之初始厚度為5.6mm。本發明之此具體實例較佳利用厚度至高達10mm之成形格式。
因鋁型膠帶或高亮度不鏽鋼板之故,該夾緊裝置較佳亦應在內表面上具有鏡面最後加工。該發泡體之格式尺寸取決於窗尺寸的設定並決定為使得該發泡體格式與該窗在長及寬方面重疊約5cm,如此可由夾架抓住。將兩個發泡體格式導入該機器的雙板框架中。該等待結合以形成中空物件之發泡體格式係定位在該工作窗上方,且使該夾架降低以將其固定就位。
根據成形程度,可改變該熱強度。在該特殊實施例中,存在使用閃光輻射器(NIR;0.78至1.40μm)之初始加熱至210℃之溫度的階段。在持續之塑化開始時,在機械空間中打入個別壓縮空氣脈衝,從而產生發泡體氣
泡。
為了成形,在加熱階段結束之後,只將底部加熱場移出該半邊工具的操作範圍,並將該成形工具從下方移至該發泡體氣泡下方。然後使該工具定位在該氣泡之下。然後儘可能迅速抽空該機器。留在其中的空氣柱導致該發泡體被拉過該工具輪廓。在整個成形過程期間,該頂部加熱器維持在其工作位置以防止發泡體冷卻。在該工具冷卻至80℃之後,可移出該結構組件,在該工具再次加熱之後,可開始下一個結構組件的製造。
如此製造之具有約260mm的內部高度之幾何形狀構成例如直昇機天線罩的突出部分。
(1)‧‧‧成形工具之頂部部分
(2)‧‧‧成形工具之底部部分
(3)‧‧‧頂部加熱器(NIR輻射器)
(4)‧‧‧底部加熱器(NIR輻射器)
(3a)及(4a)‧‧‧移除之加熱器
(5)‧‧‧發泡體核心
(6)‧‧‧夾架
(7)‧‧‧外層
Claims (9)
- 一種用於使已發泡材料成形之方法,其中該已發泡材料包含PMI,該方法包括以下步驟:a)隨意地以外層材料及在其間之發泡體核心複合層構造,b)藉由以波長介於0.78與1.40μm之間的近紅外線輻射(NIR輻射)的照射來加熱該已發泡材料,c)以成形工具成形,d)將最終工件冷卻及脫模。
- 如申請專利範圍第1項之方法,其中該加熱及成形係在兩個獨立工具中進行,且該方法中之步驟b)包括以下兩個步驟:b1)導入加熱場之機械側活性區中,b2)藉由以波長介於0.78與1.40μm之間的近紅外線輻射(NIR輻射)的照射來加熱該已發泡材料,且該方法中之步驟c)包括以下兩個步驟:c1)將該已發泡材料轉移至成形工具中,c2)以該工具成形。
- 如申請專利範圍第1項之方法,其中該加熱及成形係在一個工具中進行,且該方法中之步驟b)包括以下兩個步驟:b1)導入配備有可移除之加熱場的成形工具中, b2)藉由以波長介於0.78與1.40μm之間的近紅外線輻射(NIR輻射)的照射來加熱該已發泡材料,且該方法中之步驟c)包括以下兩個步驟:c1)從該成形工具之操作範圍移除熱,c2)以該工具成形。
- 如申請專利範圍第1項之方法,其中步驟d)包括真空成形程序。
- 如申請專利範圍第1項之方法,其中步驟d)提供該已發泡材料之局部固結。
- 如申請專利範圍第1項之方法,其中最初進料該已發泡材料之二或多個獨立件並在步驟d)中從該等件模塑中空物件。
- 如申請專利範圍第4項之方法,其中緊接在步驟c)之前或之後以壓縮空氣預成形。
- 如申請專利範圍第4項之方法,其中進行步驟a)並使用纖維強化塑膠作為外層材料。
- 如申請專利範圍第8項之方法,其中該塑膠包含PP、PE、PC、PVC、環氧樹脂、異氰酸酯樹脂、丙烯酸酯樹脂、聚酯或聚醯胺,而該纖維材料包含碳、玻璃、聚合型或芳族聚醯胺纖維。
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