Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
  • B29B17/0005—Direct recuperation and re-use of scrap material during moulding operation, i.e. feed-back of used material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/28—Shaping operations therefor
  • B29C70/40—Shaping or impregnating by compression not applied
  • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
  • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/28—Shaping operations therefor
  • B29C70/40—Shaping or impregnating by compression not applied
  • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
  • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
  • B29C70/465—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating by melting a solid material, e.g. sheets, powders of fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/28—Shaping operations therefor
  • B29C70/40—Shaping or impregnating by compression not applied
  • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/28—Shaping operations therefor
  • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
  • B29B2017/001—Pretreating the materials before recovery

Definitions

• the invention relates to a process arrangement for producing a fiber-reinforced
• fiber-reinforced plastic components can be done using textile semi-finished products, so-called prepregs.
• prepregs textile semi-finished products
• a textile fiber material having a reactive, that is to say not yet polymerized thermoplastic matrix material is preimpregnated below a polymerization start temperature.
• the prepregs are stacked in a deposition process to a layer package and subjected to a thermoforming or pressing process.
• WO 2012/116947 A1 discloses a generic process for the production of reactive prepregs, that is to say of continuous-fiber-reinforced, sheet-like semi-finished products with polyamide matrix.
• first textile structures with a liquid that is to say of continuous-fiber-reinforced, sheet-like semi-finished products with polyamide matrix.
• Starting component of the polyamide matrix that is molten lactam including added catalysts and / or activators, pre-impregnated, in one
• the preimpregnated textile endless structure is assembled in a cutting station to fiber-reinforced sheet semi-finished and stacked in a stacking station.
• the preimpregnated textile endless structure is assembled in a cutting station to fiber-reinforced sheet semi-finished and stacked in a stacking station.
• the shaping takes place, namely at a temperature above the polymerization start temperature in a press or
• the preimpregnated lactam polymerizes to a polyamide. Due to the simultaneous deep drawing / pressing, the fiber-reinforced, flat semifinished product is brought into the intended form of the component to be produced.
• a final trimming of the finished plastic component can take place, with the formation of final trimming residues, which originate from a KEST ⁇ TiGmGsm Composite composed of fibers and the polymerized matrix material.
• the Endbeites residues can be fed to a recycling station and processed there to a recyclate for applications in an injection molding or pressing process, as for example, in EP 2 666 805 B1 is indicated. Consequently, components based on a
• thermoplastic matrix can be fed by simple crushing and extruding new applications, for example in the injection molding.
• fiber composites based on a thermoplastic matrix in the excellent recycling property. By simply melting and regranulating, the fibers and the matrix mix homogeneously. The granulate recycled in this way can once again be used as a high-quality raw material for a wide variety of applications.
• edge trim remnants from the fabrication of the semifinished fiber products
• assembly trim remnants also arise at the preceding process times.
• the edge trimming residues and the Assemblierbeites residues are - unlike the Endberough residue - not yet polymerized and therefore can not be further processed in the above recycling process.
• the edge trim and assembly trim residues are therefore removed from the process chain as non-recyclable material scrap.
• the object of the invention is to provide a process arrangement and a method for producing a fiber-reinforced plastic component, which has a comparison with the prior art improved recycling concept.
• the object of the invention is characterized by the features of claim 1 or
• the process arrangement has a recycling station into which the trim residues from the composite of fibers and reactive thermoplastic matrix material can be fed.
• the recycling station provides a recyclate based on the trim residues which serves as a reactive, unpolymerized starting material for the manufacture of a component or the functionalization of a component, for example by rib structures.
• the process arrangement can be a
• Forming station to be assigned, in as a result of heat input under
• Polymerization are dried and / or in air, light and / or moisture-proof
• the shaping station can have an extruder or a metering device in which the recyclate can be melted above its melting temperature but below its reaction temperature.
• the melted recyclate is by means of the extruder or the metering device in the mold cavity of a
• Forming tool introduced, the up to a temperature above the
• Reaction temperature is heated.
• the introduction into the heated up to the reaction temperature tool can, for example, via the nozzle of an injection unit or the injection head of a dosing into an open or closed
• the recycled material may be introduced into the mold cavity of the forming station forming tool in the solid state, without prior fusing.
• the recycled material can only be melted with the tool cavity of the forming tool closed, distributed in the mold cavity and polymerized therein.
• a combination with other shaping methods for example pressing method of reactive, continuous fiber reinforced cast PA prepregs, is conceivable.
• the trimming residues carried to the recycling station may be so large that they are reduced in size prior to further processing as a recyclate, for example in a cutting mill.
• bleed residues with adjustable, uniform fiber length are present.
• both the intermediate storage of the trimming residues before and after the reduction as well as the
• the trimming residues supplied to the recycling station can have an increased fiber volume proportion compared to the volume of fibrous material of the component to be produced. Against this background, depending on the required
• Fiber volume content of the recyclate to the recycling station run trim residues a reactive matrix material and / or optionally additives, such as thickening agents, be added.
• a production engineering implementation can in the manufacturing station in a
• edge trimming is carried out, in which the pre-impregnated endless structure in a cutting station to the continuous fiber-reinforced textile semi-finished fiber products (prepregs) with reactive, that is not yet polymerized, thermoplastic matrix material is assembled. The assembly takes place with formation of edge trim residues, which consist of a composite of fibers and reactive
• edge trim residues can even be present completely without matrix material.
• the fiber content in the edge trim residues is very high.
• the prepregs are stacked and stored in a stacking station and, if necessary, transported to an assembling station.
• the prepregs are stacked in a deposition process to form a layer package.
• an Assemblierberough take place, in which the layer package is cut according to a final contour of the fiber-reinforced plastic component.
• Assemblierberough residues consisting of a composite of fibers and reactive thermoplastic matrix material.
• the assembly trim residues are completely surrounded by matrix material, that is to say fully impregnated, so that the fiber proportion corresponds to that of a finished fiber-reinforced plastic component.
• the reactive thermoplastic matrix material used is preferably caprolactam (so-called cast PA).
• Alternative reactive thermoplastic matrix systems besides caprolactam may also be, for example, laurolactam and cyclic butylene terephthalate, etc.
• fiber material all possible fibers are conceivable.
• fibers of glass, carbon (so-called carbon fibers), basalt, aramid or a combination thereof are used. These are in a variety of arrangements, such as tissue, scrims or undirectionally, before.
• the polymerization takes place in carprolactam by means of a reaction temperature of about 150 ° C, in which the polyamide (PA6) is formed from the caprolactam.
• PA6 polyamide
• temperatures adapted to the respective material should be selected.
• 5 is a block diagram of the process chain including a recycling station.
• FIGS. 1 to 4 show the process stations I to VI for producing a fiber-reinforced plastic component 1 (FIGS. 3 and 4) in so far as is necessary for the understanding of the invention.
• a production station I two fiber layers 2 are initially brought by way of example onto a continuous conveyor belt 5 in a continuous process with the interposition of a first film 3 of, for example, polyamide or another suitable material.
• the thus formed textile layer structure 7 is impregnated with an initial component 8 of a reactive thermoplastic matrix material, such as lactam, under heat application 10 at a temperature below the starting temperature for a
• a reactive thermoplastic matrix material such as lactam
• a second film 9 is applied and the textile layer structure 7 is cooled (ie consolidated) in a cooling unit 11 and, in a subsequent cutting station II, made into individual pre-impregnated textile semifinished fiber products 15.
• an edge trimming takes place in which the preimpregnated endless structure 7 is cut to the continuous fiber-reinforced textile semifinished fiber products 15 (also referred to below as prepregs).
• This produces a marginal trim residue m R which consists of a composite of fibers and reactive (that is not yet polymerized) thermoplastic matrix material.
• the edge trimming residue m R is called
• edge trim residue m R Material broke away from the process chain.
• the fibers are not completely wetted with the reactive matrix material or are present entirely without matrix material, as a result of which the edge trim residue m R has a very high fiber content.
• the prefabricated textile semi-finished fiber products 15 are stacked and stored in a following stacking station III. Depending on requirements, the semi-finished fiber packs 15 stacked on top of one another are transferred to an assembling station IV downstream of the process, which is indicated in FIG. In the Assemblierstation IV are the
• the assembly trim residue m A consists of a composite of fibers and reactive thermoplastic matrix material. In contrast to the marginal trim residue m R , in the assembly trim residue m A the fibers are completely surrounded by matrix material, that is to say fully impregnated. The fiber content of the assembly trim residue m A is therefore lower than at the edge trim residue m R and substantially identical to the fiber content of the finished plastic component 1.
• the layer package 16 is transferred to the, roughly schematic, indicated pressing and / or deep-drawing station V in FIG. 3, in which the layer package 16 is heated to a temperature above the polymerization temperature and at the same time deep-drawn into the shape of the plastic component 1 to be produced / is pressed.
• a subsequent downstream treatment station VI FIG. 4
• a plastic component 1 is attached
• Final trimming is performed, in which an example required for the thermoforming process outer component edge 17 is removed from the plastic component 1, to form a final trimming residue m E , which consists of a composite of fibers and polymerized matrix material.
• the process chain I to VI for the production of the plastic component 1 is assigned a recycling station VII, into which the not yet polymerized edge trim and assembly trim residues m Rl m A are guided.
• the recycling station VII can
• a cutting mill can be arranged, which comminutes the trimming residues m R , m A to predetermined fiber lengths.
• the trimming residues m R , m A are combined to a recyclate R, which consists of the composite of fibers and reactive thermoplastic matrix material and forms a reactive, not yet polymerized starting material for the production of a further component 19.
• the recycling station VII is followed by a forming station VIII, in which the component 19 is produced by polymerization of the recyclate R as a result of heat input.
• the forming station VIII may have an only indicated metering device 21, in which the recyclate R is melted to above its melting temperature, but still below its reaction temperature.
• the melted recyclate R is introduced by means of the metering device 21 into the tool cavity 23 of a forming tool 25, which is heated to a temperature above the reaction temperature. This means that after the introduction of the
• the recycling station VII also has an inlet 27 in FIG. 5 in order to supply the trim residues m A , m R in the recycling station VII with a reactive matrix material m ma tri X and / or optionally with additives such as thickeners. In this way, the required fiber volume content of the manufactured component 19 can be adjusted.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Composite Materials (AREA)
• Environmental & Geological Engineering (AREA)
• Reinforced Plastic Materials (AREA)
• Casting Or Compression Moulding Of Plastics Or The Like (AREA)
• Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)
• Moulding By Coating Moulds (AREA)
• Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)

Priority Applications (5)

Applications Claiming Priority (2)

Publications (1)

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Family Applications (1)

Country Status (7)

Cited By (2)

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Citations (3)

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• 2015
  • 2015-02-23 DE DE102015002107.9A patent/DE102015002107A1/de not_active Withdrawn
• 2016
  • 2016-02-15 KR KR1020177026693A patent/KR20170118894A/ko not_active Withdrawn
  • 2016-02-15 WO PCT/EP2016/000252 patent/WO2016134829A1/de not_active Ceased
  • 2016-02-15 US US15/552,939 patent/US10543648B2/en active Active
  • 2016-02-15 CN CN201680011481.3A patent/CN107249865B/zh active Active
  • 2016-02-15 EP EP16705035.0A patent/EP3261822B1/de active Active
  • 2016-02-15 JP JP2017562124A patent/JP2018507127A/ja not_active Withdrawn

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