WO2010127746A1 - Pièce moulée par injection hautement rigide et procédé de fabrication d'une pièce moulée par injection hautement rigide - Google Patents

Pièce moulée par injection hautement rigide et procédé de fabrication d'une pièce moulée par injection hautement rigide Download PDF

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Publication number
WO2010127746A1
WO2010127746A1 PCT/EP2010/001972 EP2010001972W WO2010127746A1 WO 2010127746 A1 WO2010127746 A1 WO 2010127746A1 EP 2010001972 W EP2010001972 W EP 2010001972W WO 2010127746 A1 WO2010127746 A1 WO 2010127746A1
Authority
WO
WIPO (PCT)
Prior art keywords
injection molded
molded part
reinforcing fibers
part according
fibers
Prior art date
Application number
PCT/EP2010/001972
Other languages
German (de)
English (en)
Inventor
Michael Schöbel
Steven Schmidt
Stefan Eibl
Original Assignee
Rehau Ag + Co
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 Rehau Ag + Co filed Critical Rehau Ag + Co
Publication of WO2010127746A1 publication Critical patent/WO2010127746A1/fr

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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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0005—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor using fibre reinforcements
    • 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
    • B29K2061/00—Use of condensation polymers of aldehydes or ketones 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
    • B29K2063/00—Use of EP, i.e. epoxy resins 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles

Definitions

  • the invention relates to a highly rigid injection molded part containing a plastic as the base material and reinforcing fibers to increase the mechanical stability.
  • thermoplastics for example PPS, PA
  • carbon fiber compounds with fill levels below 30% by weight carbon fibers are known. Higher fiber contents often lead to insufficient wetting of the fibers and poor dispersion. Thus, for structural components desired filling levels of more than 50% can hardly be realized.
  • the viscosity of thermal loads is very high and continues to increase with increasing fiber content.
  • the low flowability, especially at high fiber levels, leads to limitations in processing and component design.
  • injection molding with conventional screws leads to fiber length degradation by shear.
  • the invention has for its object to provide a high-stiffness injection molded part, which has a very high mechanical strength and is characterized at the same time by a high heat resistance.
  • the object is achieved by a high-stiffness injection molded part containing
  • thermosetting plastic as the base material and reinforcing fibers to increase the mechanical stability
  • the base material consists of phenolic resin and / or epoxy resin and wherein the weight fraction of the reinforcing fibers based on the entire injection-molded part is at least 30%.
  • metal parts can be substituted.
  • very high fill levels can be achieved when using the thermoset base material.
  • Phenolic resins or epoxy resins are also inexpensive raw materials.
  • the injection-molded parts according to the invention are characterized by a very high modulus of elasticity and high tensile and flexural strength due to the crosslinking and at the same time by a high heat resistance, so that they are ideally suited for use as structural components.
  • thermoplastics Due to the low weight, they have good lightweight properties compared to conventional metal components.
  • the high flame retardancy of the phenolic or epoxy resins also allows their use in applications that are subject to fire protection requirements.
  • Si-SiC ceramics can be made accessible via a pyrolysis process coupled with infiltration of silicon, which further increase the rigidity and temperature resistance. Due to the lower viscosity of thermoplastics compared to thermoplastics reinforcing fibers can be easily infiltrated here and there are much higher fiber content in the component feasible.
  • the weight fraction of the reinforcing fibers is preferably at least 50%, particularly preferably at least 60%. Conveniently, the weight fraction of the reinforcing fibers is further at most 80%, preferably at most 70%.
  • the reinforcing fibers may for example consist of carbon fibers and / or glass fibers.
  • carbon nanofibers in particular can also be used.
  • the reinforcing fibers therefore consist at least partially of nanofibers, in particular carbon nanofibers with a maximum diameter of 700 nm and a fiber length of at least 10 ⁇ m.
  • carbon nanofibers derived from polymeric nanofibers are suitable for this use.
  • fibers with a diameter ⁇ 700 nm, preferably carbon nanofibers, as long as possible it is possible for the advantageous surface volume ratio and, associated therewith, the large surface, to maximize the bonding of the reinforcing fiber to the matrix.
  • the nanofibers are almost as continuous fiber structure. Through the reaction of fiber-fiber and fiber-matrix, this tangled structure is restricted or fixed in its degrees of freedom of movement. The strong covalent bonding forces thus allow a three-dimensional energy dissipation, so that the strength of the injection molded part can be further increased.
  • ceramic fibers or metal fibers in particular boron, aluminum or silicon, or whiskers (acicular single crystals of a few micrometers in diameter and up to several hundred micrometers in length).
  • nanoscale metal oxide fibers / nanoceramic whiskers comprising titanium dioxide fibers, TiO 2 (rutile and / or anatase and / or brookite modification), and / or zirconium dioxide fibers, ZrO 2 (monoclinic alpha-ZrO 2 and / or tetragonal beta-ZrO 2 and / or cubic gamma-ZrO 2), and / or Dialuminumtrioxidmaschinen, Al 2 O 3 (hexagonal les alpha-Al 2 O 3 and / or gamma-Al 2 O 3 having a cubic closest packing), and / or nanoscale Mischoxidmaschinen comprising Al 2 O 3 and / or TiO 2 and / or ZrO 2 and / or Y 2 O 3 and / or B 2 O 3 and / or SiO 2 and / or FeO and / or Fe 2 O 3 and / or Na 2 O and / or CaO and / or MgO and / or K 2
  • fibers of silicon carbide or silicon nitride or boron nitride or titanium carbide may be used to reinforce the injection molded part.
  • basalt fibers Furthermore, it may be advantageous to use basalt fibers.
  • synthetic reinforcing fibers include, for example, aramid, polyamide and polyester fibers, and also polyacrylonitrile or preoxidized polyacrylonitrile or polyimide fibers.
  • natural fibers can be used as reinforcing fibers.
  • plant fibers are particularly preferred. These can be selected from cotton, kapok, poplar fluff, bamboo, nettle, hemp, jute, linen, ramie, sisal, manila hardwood, coconut, cellulose, miscanthus and wood.
  • the length of the reinforcing fibers is preferably at least 5 mm, more preferably at least 10 or at least 20 mm. Furthermore, the reinforcing fibers are preferably arranged substantially in the direction of the forces acting in the injection molded part during operation / use. As a result, the reinforcing fibers can optimally contribute to increasing the mechanical strength of the injection-molded part.
  • the reinforcing fibers are surface treated.
  • the surface treatment can be carried out, for example, by PVD (physical vapor deposition), CVD (chemical vapor deposition), oxidation treatment and / or sizing, typically epoxy or modified epoxy resins.
  • the surface treatment of the fibers is particularly useful to allow coating of the fibers with the base material prior to injection molding. Such a coating of the reinforcing fibers prior to the reactive injection molding process optimizes the incorporation or dispersion of the fiber in the base material and reduces fiber degradation during processing.
  • the base material for weight reduction may contain micro-glass bubbles. These hollow microspheres preferably have a diameter of 10 to 30 .mu.m, preferably 15 to 25 .mu.m. These are expediently distributed substantially uniformly in the base material and, owing to their small size, can lead to a significant weight saving, without the mechanical properties of the injection-molded part being impaired as a result.
  • the phenolic resin is formed as a condensation product of phenol and / or phenol derivatives with formaldehyde.
  • Substituted phenols in particular alkyl-substituted phenols, such as, for example, are used as phenol derivatives.
  • Preferred starting materials are highly ortho-substituted novolacs, which are particularly reactive due to their structure, but show no self-condensation.
  • crosslinkers in particular formaldehyde donors, such. Hexamethylenetetramine, trioxane or paraformaldehyde in question.
  • Further additives may be crosslinking aids, catalysts, lubricants, release agents, flame retardants and / or stabilizers.
  • the phenolic resin and / or epoxy resin is present as a mixture or co-condensation product with at least one further thermoset resin.
  • thermoset resin for example, benzoxazines, cyanate esters, phenol-epoxy resins or melamine resins can be used.
  • silazanes in particular polysilazanes, polysilanes, polycarbosilanes, polycarbosilazanes, polysilyl carbodiimides, polysilazilazanes and boron-nitrogen compounds, such as 2,4,6-tris (methylamino) borazine or poly [B- ( methylamino) borazine].
  • These compounds are thermally cleavable and crosslinkable. Hydrosilylation, decoupling and transamination reactions as well as reactions on the vinyl group can both catalyze and initiate crosslinking reactions / surface reactions.
  • the resulting cleavage products are also functional anchor groups for attachment to the reinforcing fiber.
  • substances are additionally present which react in the adsorption of low molecular weight compounds with the release of energy.
  • These substances may contain the elements silicon (Si), magnesium (Mg), aluminum (AI), calcium (Ca), oxygen (O), zinc (Zn), phosphorus (P) and are, for example, zeolites or quicklime or clay minerals.
  • the released heat of adsorption can be used to locally accelerate the crosslinking reaction in a kinetically controlled manner.
  • the invention further relates to a method for producing a highly rigid injection molded part according to one of claims 1 to 10, wherein a thermosetting plastic of phenolic resin and / or epoxy resin is used as the base material and wherein the injection molded part by reinforcing fibers having a weight fraction of at least 30% - based on the entire injection molded part - is reinforced.
  • the reinforcing fibers can already be coated with a part of the base material before the reactive injection molding process.
  • the reinforcing fibers contribute to accelerating the curing process on the surface of the already partially cured matrix polymer.
  • Koibenhubtechnologie is preferably used.
  • the reactive mass is pressed into the cavity, wherein the shearing of the mass, for example by screws, is kept as low as possible in order to obtain the reinforcing fibers largely undamaged.
  • the injection molding tool can be filled with longer fibers, for example continuous fibers, but also with fabrics or braids made of reinforcing fibers. Furthermore, this orientation of the fibers is possible.
  • the highly rigid injection-molded parts according to the invention are used, for example, as aircraft component, in particular interior component (eg as luggage compartment partition, so-called partition wall) or as load-bearing aircraft.
  • aircraft component in particular interior component (eg as luggage compartment partition, so-called partition wall) or as load-bearing aircraft.
  • interior component eg as luggage compartment partition, so-called partition wall
  • load-bearing aircraft e.g as luggage compartment partition, so-called partition wall
  • Other applications arise in the automotive industry, including caravan construction, aircraft, ships and rail vehicles.Applications generally open up for load-bearing and force-absorbing and -transporting components, which are referred to as "structural components or "construction components”. Applications can find the injection molded parts in furniture, for the production of sports equipment, in medical technology, agriculture, in installation technology and tank construction, as well as industrial shelving.
  • the high-strength injection-molded parts according to the invention can also be used for the construction of windows, doors, facades, floors, ceilings and walls in building construction and in addition in civil engineering. Also, the traffic route construction and the construction of construction, for example, bridges, can benefit from this invention advantageous.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

L'invention concerne une pièce moulée par injection hautement rigide. Cette pièce moulée par injection contient un plastique thermodurcissable en tant que matériau de base et des fibres de renforcement pour augmenter la stabilité mécanique. Le matériau de base est constitué de résine phénolique et/ou de résine époxy, la proportion en poids des fibres de renforcement par rapport à la pièce moulée par injection totale s'élève au moins à 30 %. En outre, l'invention concerne un procédé de fabrication de pièces moulées par injection hautement rigides ainsi que leur utilisation.
PCT/EP2010/001972 2009-05-08 2010-03-29 Pièce moulée par injection hautement rigide et procédé de fabrication d'une pièce moulée par injection hautement rigide WO2010127746A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102009020448.2 2009-05-08
DE200910020448 DE102009020448A1 (de) 2009-05-08 2009-05-08 Hochsteifes Spritzgussteil sowie Verfahren zur Herstellung eines hochsteifen Spritzgussteils

Publications (1)

Publication Number Publication Date
WO2010127746A1 true WO2010127746A1 (fr) 2010-11-11

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2010/001972 WO2010127746A1 (fr) 2009-05-08 2010-03-29 Pièce moulée par injection hautement rigide et procédé de fabrication d'une pièce moulée par injection hautement rigide

Country Status (2)

Country Link
DE (1) DE102009020448A1 (fr)
WO (1) WO2010127746A1 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102012111606A1 (de) * 2012-11-29 2014-04-10 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Zylindergehäuse
DE102015209324A1 (de) 2015-05-21 2016-11-24 Schaeffler Technologies AG & Co. KG Planetenträger aus faserverstärktem Kunststoff

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2012688A1 (de) * 1968-09-19 1972-02-17 Bolidt Mij Tot Exploitatie Van Verfahren und Vorrichtung zum Herstellen von Formkorpern aus Fasern enthaltendem Kunstharz
DE2166208A1 (de) * 1970-12-28 1973-08-09 Usm Corp Verfahren zur herstellung verstaerkter kunststoffgegenstaende
US4340562A (en) * 1980-01-18 1982-07-20 Union Carbide Corporation Process for producing a molded article
EP0653291A2 (fr) * 1993-10-14 1995-05-17 Ciba-Geigy Ag Articles moulés
US5424020A (en) * 1989-08-21 1995-06-13 Sumitomo Chemical Company, Limited Method for producing molded article of fiber-reinforced thermoplastic resin
US7175796B2 (en) * 2000-09-29 2007-02-13 Menzolit-Fibron Gmbh Method for producing ceramic brake disks from bmc
WO2008141201A1 (fr) * 2007-05-10 2008-11-20 Fish Christopher N Matériaux composites

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH089186B2 (ja) * 1990-07-31 1996-01-31 住友ゴム工業株式会社 耐衝撃用具および該耐衝撃用具の製造方法
DE4233406B4 (de) * 1992-10-05 2005-01-27 Zf Sachs Ag Kupplungsscheibe mit einer Kunststoffnabe
DE19921712A1 (de) * 1999-05-12 2000-11-23 Ticona Gmbh Kunststoffgehäuse mit verringertem Verzug
EP1523388B1 (fr) * 2002-07-04 2011-02-09 Klaus Katzfuss Dispositif de maintien en position fermee
US7716828B2 (en) * 2004-05-31 2010-05-18 Aisan Kogyo Kabushiki Kaisha Method of manufacturing throttle body, and throttle body

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2012688A1 (de) * 1968-09-19 1972-02-17 Bolidt Mij Tot Exploitatie Van Verfahren und Vorrichtung zum Herstellen von Formkorpern aus Fasern enthaltendem Kunstharz
DE2166208A1 (de) * 1970-12-28 1973-08-09 Usm Corp Verfahren zur herstellung verstaerkter kunststoffgegenstaende
US4340562A (en) * 1980-01-18 1982-07-20 Union Carbide Corporation Process for producing a molded article
US5424020A (en) * 1989-08-21 1995-06-13 Sumitomo Chemical Company, Limited Method for producing molded article of fiber-reinforced thermoplastic resin
EP0653291A2 (fr) * 1993-10-14 1995-05-17 Ciba-Geigy Ag Articles moulés
US7175796B2 (en) * 2000-09-29 2007-02-13 Menzolit-Fibron Gmbh Method for producing ceramic brake disks from bmc
WO2008141201A1 (fr) * 2007-05-10 2008-11-20 Fish Christopher N Matériaux composites

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Publication number Publication date
DE102009020448A1 (de) 2010-11-11

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