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
  • 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
  • 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
  • B29C70/50—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
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/50—Reuse, recycling or recovery technologies
  • Y02W30/62—Plastics recycling; Rubber recycling

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 this is 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 end trimming residues, which consist of a
• thermoplastic matrix can be fed by a simple crushing and extruding new applications in injection molding.
• Fiber composites based on a thermoplastic matrix in excellent recycling properties. 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.
• the problem is that - apart from the end trim remainder mentioned above - edge trim remnants (from the fabrication of the semifinished fiber products) and assembly trim remnants are also produced at upstream 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 recycling station is additionally assigned a treatment station.
• the preparation station are trimming residues from a composite of fibers of not yet polymerized, that is reactive thermoplastic matrix material fed.
• the processing station first the reactive
• the composite material supplied by the treatment station is further processed together with the Endberough-residues to the recyclate, which is suitable for applications in injection molding or pressing processes.
• the treatment station With a view to proper polymerization in the treatment station, it is of
• the polymerization of the bleed residues takes place in an oven, for example in a continuous furnace.
• a production engineering implementation can in the manufacturing station in a
• edge trim residues consist of a composite of fibers and reactive thermoplastic matrix material.
• the fibers are not completely wetted with the matrix material due to production engineering.
• the edge trim remnants can sometimes even be completely without matrix material.
• the fiber content in the edge trim residues is very high.
• the prepregs are initially stacked on top of one another in a laying process to form a layer package. Subsequently, an Assemblierberough done, in which the layer package corresponding to a final contour of the fiber-reinforced
• Plastic component is cut. This is done to form Assemblierberough- residues, consisting of a composite of fibers and reactive thermoplastic
• Fiber content is relatively large and corresponds to the fiber content of a finished fiber-reinforced plastic component.
• the Assemblierberough and then the deposition process can be done first.
• the reactive prepregs may be formed with an outer component edge which has a projection required for the pressing and / or deep-drawing process forms. This is functionless after the pressing and / or deep-drawing process and can therefore be removed from the finished plastic component in the post-treatment station, with the formation of Endberough residues. At the same time breakthroughs, recesses or the like can be incorporated into the finished plastic component in the post-treatment station, which also Endberough remains arise, which
• the supernatant removed from the plastic component may have a fiber content that is identical to the fiber content of the finished plastic component.
• the removed supernatant may also have a lower fiber content, due to an overflow of excess atrix material during the molding of the plastic component in the press / deep draw tool.
• Recyclates to be produced can be added to the recycling station led trimming residues a pure polymerized matrix material.
• the processing station and / or the recycling station can be assigned a comminution unit, for example a granulator, in which the clippings which can be brought together to form the recyclate
• the edge trimming residues and the Assemblierberough- residues can be polymerized before the granulator processing.
• the Endbetre rest can be mixed depending on the requirements with the Assemblierberough-rest and / or with the Randberough- remainder before or after the granulator in different weight ratios with each other and only then the recycling station. Therein then the further processing of short or long fiber reinforced, polymerized
• 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, scrim or unidirectional before.
• the polymerization takes place in caprolactam by means of a
• Reaction temperature of about 150 ° C at which the caprolactam polyamide (PA6) is formed.
• PA6 caprolactam polyamide
• temperatures adapted to the respective material should be selected.
• 5 is a block diagram of the process chain including a recycling station and an associated conditioning 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).
• prepregs continuous fiber-reinforced textile semifinished fiber products
• the fibers are not completely wetted with the reactive matrix material or they are entirely without matrix material, whereby the marginal trim residual 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.
• edge trimming residue m R are in
• Assemblierbeites rest m A the fibers completely surrounded by matrix material, that is fully impregnated.
• the fiber fraction of the assembly trim residue m A is therefore higher than the marginal trim residue m R and substantially identical to the fiber fraction 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 producing the plastic component 1 is a
• the recycling station VII may optionally be arranged a cutting mill, which the
• the recycling station VII the end trimming residues m E are further processed into a recyclate R, which is suitable for use in an injection molding or pressing process.
• the recycling station VII is assigned a treatment station VIII.
• the processing station VIII are the edge trim residues m R and the
• trim residues m R , m A consist of a composite of fibers with reactive (that is, not yet polymerized) thermoplastic matrix material and are therefore not directly in the recycling station VII to the recyclate R processable.
• the reactive thermoplastic matrix material of the two trimming residues m R , m A is polymerized.
• polymerized matrix material is then combined in the recycling station VII with the Endberough- residues m E and further processed there.
• the treatment station VIII may also have a cutting mill in which the trimming residues m R and m A are comminuted. It is preferred if the cutting mill processing of the edge trim and the assembly trim residues m R , m A only takes place after they have been polymerized.
• Embodiment variant of the Endberough rest m E at one, the recycling station VII upstream coupling point 21 are merged with the polymerized bleed residues m A , m R and then forwarded to the recycling station VII.
• the recycling station VII upstream coupling point 21 are merged with the polymerized bleed residues m A , m R and then forwarded to the recycling station VII.
• polymerized matrix material may be added to optionally the fiber content in
• admixtures can be added to the recycled material R produced in the recycling station VII.
• the recyclate R can be plasticized in the further course of the process and fed to a screw extruder and then processed in the injection molding or pressing process.

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

Family Cites Families (16)

• 2015
  • 2015-02-23 DE DE102015002106.0A patent/DE102015002106A1/de not_active Withdrawn
• 2016
  • 2016-02-15 CN CN201680011510.6A patent/CN107257731B/zh active Active
  • 2016-02-15 US US15/552,987 patent/US11034102B2/en active Active
  • 2016-02-15 JP JP2017562125A patent/JP2018507128A/ja not_active Withdrawn
  • 2016-02-15 KR KR1020177026692A patent/KR20170118893A/ko not_active Withdrawn
  • 2016-02-15 EP EP16705425.3A patent/EP3261823B1/de active Active
  • 2016-02-15 WO PCT/EP2016/000254 patent/WO2016134830A1/de not_active Ceased

Patent Citations (3)

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