WO2017084851A1 - Moule, procédé pour le produire et son utilisation - Google Patents

Moule, procédé pour le produire et son utilisation Download PDF

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Publication number
WO2017084851A1
WO2017084851A1 PCT/EP2016/075915 EP2016075915W WO2017084851A1 WO 2017084851 A1 WO2017084851 A1 WO 2017084851A1 EP 2016075915 W EP2016075915 W EP 2016075915W WO 2017084851 A1 WO2017084851 A1 WO 2017084851A1
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WO
WIPO (PCT)
Prior art keywords
water
soluble
binder
particles
polymer
Prior art date
Application number
PCT/EP2016/075915
Other languages
German (de)
English (en)
Inventor
Ivo Herzog
Original Assignee
H2K Minerals Gmbh
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 H2K Minerals Gmbh filed Critical H2K Minerals Gmbh
Priority to EP16791348.2A priority Critical patent/EP3377289A1/fr
Priority to CN201680079641.8A priority patent/CN108602211A/zh
Publication of WO2017084851A1 publication Critical patent/WO2017084851A1/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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
    • B29C33/52—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles soluble or fusible
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/3842—Manufacturing moulds, e.g. shaping the mould surface by machining
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
    • B29C33/54—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles made of powdered or granular 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/3807—Resin-bonded materials, e.g. inorganic particles
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/3814—Porous moulds
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/40—Plastics, e.g. foam or rubber
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/76—Cores
    • 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
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/22—Component parts, details or accessories; Auxiliary operations
    • B29C39/26—Moulds or cores
    • B29C39/34—Moulds or cores for undercut articles
    • 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
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/40—Removing or ejecting moulded articles
    • B29C45/44—Removing or ejecting moulded articles for undercut articles
    • B29C45/4457—Removing or ejecting moulded articles for undercut articles using fusible, soluble or destructible cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing

Definitions

  • the invention described below relates to the production of fiber composite bodies or castings of plastic or metal serving molds, their preparation and their use.
  • the invention particularly relates to the production of cavities in fiber composite bodies or castings of plastic or metal serving cores.
  • components of metal, plastic or a fiber composite material (a composite material comprising a matrix of a plastic and a fiber material embedded in the matrix) are used, which have a cavity in its interior.
  • the manufacture of such components is difficult, in particular if the cavity is to have a complex geometry, for example an elongated, curved shape or a shape with undercuts, while at the same time the cavity surface must be smooth and of high quality.
  • One possible way of producing such components in one piece is casting using so-called “lost molds.” In this technique, in a preliminary step, a molding (the so-called “core”) is produced in size and shape forming cavity corresponds.
  • the core is arranged in a casting mold consisting of further molded parts, into which subsequently a liquid metal, polymer material or a liquid polymer precursor is injected.
  • the core is clad with a fibrous material prior to placement in the casting tool. After casting you get a fiber composite body or a casting of metal or plastic with the desired cavity, in which, however, still the core is inserted. This is then removed, which can not be done without destruction of the core due to the mentioned complex geometry of the cavity.
  • the core is "lost" as a molded part.
  • a core In order to remove a core from a cavity of complex geometry, it can be crushed, for example, or converted into a liquid or at least flowable state.
  • the prerequisite for this is a suitable condition of the core.
  • melt-core injection molding a special form of plastic injection molding
  • the core is made from a low-melting metal or a low-melting alloy.
  • the core is placed in a casting tool and molded with plastic.
  • the resulting casting, including the core contained therein, is transferred to a heating bath to melt the core.
  • the heating bath is adjusted to a temperature slightly above the melting point of the low-melting metal or the low-melting alloy, so that the injection molded part is not damaged.
  • the melting time can be shortened by inductive heating of the core metal. Liquid core metal collects at the bottom of the heating bath and can be used to make new cores.
  • the required low-melting metals or alloys are relatively expensive.
  • the metals and alloys are limited in the processing of polymers with low processing temperatures such as polypropylene and polyethylene.
  • Fiber composite components are often fabricated using inflatable tubing that can be placed in place of cores in a casting tool. These are usually closable tubes made of a silicone, which can be applied during a casting process from the inside with a pressure. After completion of the casting process, the pressure is released and the hose is removed.
  • the hoses used are basically reusable. However, they are thermally and mechanically only limited stability, which sets their reusability in practice narrow limits. Moreover, they are only limitedly suitable for the production of cavities with complex geometries.
  • cores made of sand for the production of cavities in castings.
  • cores can also be used in plastic molding, provided that their surface is sealed (for example, by applying a heat-shrinkable tube to the core).
  • They are made from a molding material mixture comprising a binder and the sand as a particulate molding material.
  • the binder holds the particles of mold base together and thus accounts for the structural integrity of the cores.
  • the cores must be able to withstand the thermal and mechanical stresses occurring during a casting process. After casting, the cores are usually crushed by vibration.
  • a water-soluble binder such as a binder based on magnesium sulfate, water glasses or based on polyphosphate and / or borate, the cores can be solved by the casting process with water from castings obtained.
  • Such cores are basically also suitable for processing polymers with low processing temperatures.
  • the cores often lack the required strength and also the required shelf life.
  • Water-soluble binder materials are often hygroscopic and thus store water in moist environments, which can significantly reduce their binding effect.
  • the present invention has for its object, for the production of fiber composite bodies or castings from metal or plastic serving molds, in particular for the production of cavities in fiber composite bodies or castings made of metal or plastic serving cores to provide that are inexpensive to manufacture and offer a wide range of applications.
  • the shapes and cores should have a high strength with high storage stability.
  • the mold according to the invention is used in particular for the production of fiber composite bodies or in cast parts made of plastic. But it can also serve for the production of castings made of metal. In many cases, the mold according to the invention may also be a core for producing cavities.
  • the mold comprises a particulate mold base and a binder and has pores.
  • the binder is a water-soluble binder.
  • the shape is characterized by the following feature:
  • the pores are at least partially filled with the pore filling material, in preferred embodiments also completely.
  • the openings have towards the surface of the mold.
  • the pore filling material not only fills said pores but also covers the surface of the mold.
  • the pore filling material is preferably chemically inert with respect to the binder and / or with respect to the particulate molding base material. With particular preference it is chemically inert both to the binder and to the particulate molding material. It is further preferred that the pore-filling material is solid at room temperature (20 ° C) and normal pressure (1 bar).
  • the term "chemically inert" is to be understood in the present case that the pore filling material does not or only to a small extent undergoes a reaction, in particular a chemical reaction, when it is processed with the binder and / or the mold base material. that it does not weaken the structural integrity of the core in direct contact with the binder and / or the pore-filling material, in particular, it does not dissolve the binder used.
  • the term "liquefiable by increasing the temperature” is to be understood as meaning that the pore filling material changes from the solid to a liquid state when the temperature increases and thus has a melting point or at least a melting range.
  • the pore filling material is liquefiable by raising the temperature to a temperature in the range between 20 ° C and 500 ° C, preferably between 20 ° C to 380 ° C. Within these ranges, the following ranges may be further preferred:
  • the particulate molding base preferably consists of or comprises at least one of the following components or a combination of at least two of the following components one of the following components or a combination of at least two of the following components:
  • 2a particles of inorganic, water-insoluble materials include in particular sand, glass, ceramics, glass ceramics, glass frits, silicates such as aluminum silicate, metal oxides such as aluminum oxide, metal nitrides, titanates, zirconates, aluminates, carbide, for example silicon carbide, metals, metal alloys, graphite particles, water-insoluble or sparingly soluble in water salts such as barium sulfate or calcium carbonate.
  • the sand particles are preferably particles of a refractory, mineral sand.
  • the sand can be natural or synthetic. Quartz sand, zircon sand, chrome ore sand, mullite sand and olive sand are particularly suitable.
  • glass particles means in the present case in particular all particles of inorganic glasses which are chemically inert to water or aqueous solutions, at least in the temperature range between 0 ° C and 200 ° C.
  • Particles of carbides, nitrides, oxides, silicides and known clay minerals such as, for example, kaolinite are to be understood as meaning ceramic particles.
  • glass-ceramics glass which has crystalline ceramic particles embedded in an amorphous glass phase.
  • Glass frits occur as intermediates in the production of glass melts. By superficially melting a glass powder, the individual particles of the powder bake together. Canceling the melting process at this point yields a porous body called glass frit.
  • the term "frit” is also applied to particles and powder obtained from this body by milling.
  • particles of light metals such as aluminum, as metal particles.
  • metal particles or low-melting particles for example of a low-melting glass
  • molds which are suitable for the production of fiber composite bodies or castings Plastic serve.
  • liquid metals such as liquid aluminum
  • sand and ceramic particles are particularly suitable as mold base material.
  • 2b Particles of inorganic, water-soluble materials include, in particular, salts from the group consisting of sodium chloride (NaCl), potassium chloride (KCl) and sodium carbonate (Na2COs). Also included are nitrates, especially sodium nitrate (NaN0 3 ) and potassium nitrate (KN0 3 ).
  • the salts mentioned are particularly suitable for molds for the production of fiber composite bodies or castings made of plastic.
  • 2c Particles of organic, water-insoluble materials include in particular water-insoluble polymer materials such as polystyrene, polyethylene, polypropylene, polyurethane and polycarbonate.
  • the polymer materials mentioned are particularly suitable for molds for the production of fiber composite bodies or castings from low-melting plastic.
  • 2d particles of organic, water-soluble materials include in particular water-soluble polymers such as polyvinyl alcohol (PVA) or salts of organic acids, for example sodium acetate.
  • PVA polyvinyl alcohol
  • salts of organic acids for example sodium acetate.
  • the materials mentioned are particularly suitable for molds for producing fiber composite bodies or castings from low-melting plastic.
  • Particles of an Inorganic-Organic Composite Material include, for example, composite materials of one of the polymer materials mentioned in 2c or 2d, in which inorganic particles, for example from one of the materials mentioned under 2a, are embedded.
  • Inorganic-organic composite materials are particularly suitable for molds for the production of fiber composite bodies or castings from low-melting plastic.
  • the particles of the particulate molding material may be present as spheres or as hollow spheres.
  • the particles of the particulate basic molding material preferably have an average particle size ⁇ 1000 ⁇ m, preferably ⁇ 600 ⁇ m. Particular preference is given to particles having average particle sizes in the range from 50 ⁇ m to 500 ⁇ m.
  • the particulate mold base is free of water, preferably also free of water of crystallization, as long as the mold base is a salt.
  • glycerol or a common surfactant may be added to the particulate mold base.
  • the pore filling material used in particular when it is a salt, can penetrate into the pores more easily.
  • the water-soluble binder is preferably one of the following binders or a combination of at least two of the following binders:
  • a Water-Soluble Inorganic Binder include, most preferably, water glass based binders, magnesium sulfate based binders, or phosphate and / or borate based binders.
  • Water glasses are both solidified from a melt, glassy, water-soluble alkali metal silicates, especially sodium, potassium, and lithium silicates, as well as their aqueous solutions.
  • Sodium water glasses are particularly suitable for use in the context of the present invention. It is also possible to use a mixture of two or more different water glasses.
  • a characteristic feature of water glasses is their modulus, which is understood to mean the molar ratio Si02: M2 ⁇ D in the water glass, where M is preferably selected from Li + , K + or Na + .
  • M is preferably selected from Li + , K + or Na + .
  • water glasses are preferably used whose modulus is in the range of 1, 5 to 3.3.
  • alkali water glass is described, which is also suitable in the context of the present invention as a binder and cured by the introduction of CO2 can be.
  • Further suitable water-glass-based binders are known, for example, from DE 199 25 167 A1, DE 10 2007 045 649 A1 or from US Pat. No. 5,474,606 A.
  • Borates are salts or esters of boric acids. Boric acid itself can be counted among the borates, it is often referred to as trihydrogen borate.
  • the salts are characterized in that they contain in their ion lattice as anion the borate ion BO3 3 " or a condensed form thereof (for example ⁇ 4 ⁇ 5 ( ⁇ ) 4 2 , tetraborate).
  • Polyphosphates are known to be condensation products of ortho-phosphoric acid salts (H3PO4) with the general empirical formula Iv PnC n + i and the structure M-O- [P (OM) (O) -O] n -M, where M is a monovalent metal and n can easily be up to three or even four digits.
  • the polyphosphates however, very often also the short-chain (ie actually oligo-) phosphates are counted, where n may be, for example, a number from 8 to 32. Cyclic polymers are referred to as metaphosphates.
  • Binders based on polyphosphate and / or borate suitable for use in the context of the present invention are described, for example, in WO 92/06808 A1. Further suitable phosphate-based binders are known from DE 103 59 547 B3 or from DE 195 25 307 A1 or from US Pat. No. 5,711,792 A.
  • the binder used in the invention comprises sodium hexametaphosphate ((NaPOs) 6) as the phosphate.
  • a water-soluble organic binder include in particular binders based on water-soluble polymers, for example based on polyvinyl alcohol (PVA).
  • PVA polyvinyl alcohol
  • Polyvinyl alcohol is known to be a thermoplastic material, which is usually produced by saponification of polyvinyl acetate. The plastic is usually processed in the form of an aqueous solution. Its melting point is usually in the range of 200 ° C to 228 ° C, depending on the degree of hydrolysis and polymerization.
  • the water-soluble binder is one of the following binders or a combination of the following binders:
  • a water-glass-based binder with a proportion of a synthetic or natural silicon dioxide Such binders are known, for example, from EP 1 802 409 B1 and from DE 10 2007 045 659 A1.
  • the binder used is a polyphosphate
  • a borate is used as the binder, it is preferably a polyborate of the general formula M n -2B n O 2 n- 1 or a metaborate of the general formula (B 2 O) n n .
  • Mixtures of magnesium sulfate and phosphate and / or borate are particularly preferred.
  • liquid metals for example of liquid aluminum
  • forms which have a water glass-based binder.
  • all of the binders mentioned are generally suitable for the production of molds which serve to produce fiber composite bodies or cast parts made of plastic.
  • the pore filling material is preferably one of the following substances or a combination of at least two of the following substances:
  • b is a water-soluble, meltable polymer, for example polyethylene glycol or low molecular weight polypropylene glycol, in particular having a melting point in the range from 20 ° C to 70 ° C.
  • c is a water-insoluble, meltable polymer, for example a low-melting thermoplastic polyamide or an ethylene-vinyl acetate copolymer, in particular having a melting point in the range of 50 ° C to 150 ° C, more preferably having a melting point in the range of 50 ° C to 100 ° C.
  • a low melting point metal or alloy such as is used to make cores for the aforementioned melt core injection molding, for example, bismuth or a bismuth alloy, especially having a melting point in the range of 50 ° C to 150 ° C, especially preferably having a melting point in the range from 50 ° C to 100 ° C.
  • a water-soluble salt or a mixture of two or more water-soluble salts in particular a melt of the water-soluble salt or a molten mixture (melt) of the two or more water-soluble salts.
  • salts of salts which are composed of cations of the alkali metals and alkaline earth metals and of anions of the types chloride, nitrite, nitrate, carbonate, hydroxide, fluoride, cyanate and sulfate are particularly suitable.
  • nitrates such as lithium, potassium or sodium nitrate or nitrites such as lithium, potassium or sodium nitrite or mixtures containing a nitrate or nitrite or preferably two or more nitrates and / or nitrites.
  • nitrates such as lithium, potassium or sodium nitrate or nitrites
  • mixtures containing a nitrate or nitrite or preferably two or more nitrates and / or nitrites.
  • a ternary mixture having a melting temperature of 142 ° C. from 40% by weight NaNO 2, 7% by weight NaNC and 53% by weight KNO 3.
  • a suitable binary mixture of 45 wt .-% NaNÜ2 and 55 wt .-% KNO3 has a melting temperature of 141 ° C.
  • the salt mixtures may also contain chlorides, for example magnesium chloride, potassium chloride and / or sodium chloride.
  • formates and tartrates in particular potassium formate and sodium tartrate, optionally also a mixture of potassium formate and sodium formate.
  • pore-filling material used is preferably exclusively salts and salt mixtures which are free from water, in particular also free from water of crystallization.
  • salts and salt mixtures having a dynamic viscosity of less than 4 mPas (at 300 ° C.), preferably less than 3 mPas (at 300 ° C.), more preferably less than 2.5 mPas (at 300 ° C.). used.
  • the salts and salt mixtures have a melting point in the range of 20 ° C to 500 ° C, preferably from 30 ° C to 380 ° C.
  • the salts and salt mixtures may have a melting point in the range of from 30 ° C to 300 ° C, preferably from 30 ° C to 150 ° C.
  • Urea is known to be a non-toxic and hygienically safe solid with a melting range of 132.5 to 134.5 ° C, which has excellent water solubility.
  • At least one water-soluble sugar in particular from the group with mannose and galactose.
  • At least one water-soluble polyalcohol in particular from the group with sorbitol and mannitol.
  • the mentioned organic pore filling materials are basically not suitable for processing liquid metals such as aluminum. In particular, some of the salts and salt mixtures mentioned are more suitable for this purpose. On the other hand, all the mentioned pore filling materials are generally suitable for the production of molds which serve for the production of fiber composite bodies or cast parts made of plastic. In many embodiments, it is quite fundamentally preferred that the pore-filling material is a material which is not water-soluble and has a melting point below the melting point of the particulate molding material used, preferably at least 20 ° C below the melting point, in particular at least 50 ° C. This temperature difference is particularly relevant if particles of organic materials are used as the particulate molding material.
  • the melting point of the pore-filling material plays a comparatively minor role.
  • the pore filling material be liquefiable by raising the temperature to a temperature in the range between 20 ° C and 140 ° C.
  • the pore filling material in the form - based on its total volume - in a proportion of 1 to 80 vol .-%, preferably from 1 to 50 vol .-%, particularly preferably from 10 to 50 vol .-%, is included. It fills the pores of the mold preferably more than 25%, in particular more than 50%, particularly preferably more than 75%, from. In some embodiments, all pores of the mold are filled with the pore filling material. In some other embodiments, the pores lying at and below the surface of the mold are filled with the pore-filling material while pores not filled with pore-filling material exist inside the mold.
  • molds having the following combinations of mold base, binder and pore filler are particularly preferred:
  • An organic water-insoluble and / or an inorganic water-insoluble material is used as the particulate molding material.
  • a water-soluble inorganic binder is used.
  • pore-filling material one of said water-soluble materials, for example urea or one of said water-soluble salts or a water-soluble polymer, is used.
  • a core made from this combination of mold base, binder, and pore filler material is usually cast after casting from a casting easily dissolve with water. Because both the pore filler and the binder are water soluble, the core quickly loses its structural integrity upon contact with water and disintegrates.
  • an organic water-insoluble and / or an inorganic water-insoluble material is used as the particulate molding base material.
  • the binder used is a water-soluble inorganic binder.
  • the pore-filling material one of the above water-insoluble materials, for example, a natural or synthetic wax, fat or oil, or a water-insoluble fusible polymer or a metal or a metal alloy (both low-melting) is used.
  • a core made from this combination of mold base, binder and pore filling material is characterized in that it is hydrophobic due to the hydrophobic pore filling material. He is therefore not water-soluble on his own. However, when heating the core, the pore-filling material melts and the water-soluble binder can come into direct contact with water, for example the water of a water bath. The then beginning solution process results in a decomposition of the core.
  • an organic water-insoluble and / or an inorganic water-insoluble material is used as the particulate molding base material.
  • the binder used is a water-soluble organic binder.
  • As pore-filling material one of said water-soluble materials, for example urea or one of said water-soluble salts or a water-soluble polymer, is used.
  • a core made from this combination of mold base, binder and pore filler behaves in contact with water similar to a core according to Fig. 7a.
  • d As the particulate molding base material, an organic water-insoluble and / or an inorganic water-insoluble material is used.
  • the binder used is a water-soluble organic binder.
  • the pore-filling material one of the above water-insoluble materials, for example, a natural or synthetic wax, fat or oil, or a water-insoluble fusible polymer or a metal or a metal alloy (both low-melting) is used.
  • a core made from this combination of mold base, binder and pore filler behaves similar to a core according to Fig. 7b. 7e
  • an organic water-soluble and / or an inorganic water-soluble material is used.
  • the binder used is a water-soluble inorganic or organic binder.
  • the pore-filling material one of the above water-insoluble materials, for example, a natural or synthetic wax, fat or oil, or a water-insoluble fusible polymer or a metal or a metal alloy (both low-melting) is used.
  • a core made from this combination of mold base, binder and pore filler behaves similar to a core according to Fig. 7b.
  • the binders based on polyphosphate and / or on borate and also on magnesium sulfate-based binders are combined with pore-filling materials which are anhydrous, in particular also have no water of crystallization.
  • pore-filling materials which are anhydrous, in particular also have no water of crystallization.
  • anhydrous salts described above or mixtures of two or more water-soluble salts are especially suitable for this purpose.
  • the present invention further relates to a method for producing a body for the production of fiber composite or castings made of plastic or metal mold, in particular for producing a body for producing voids in fiber composite or castings made of plastic or metal core, more preferably a mold or a Kerns, as described above.
  • a mold having pores is first produced from one of the described particulate mold raw materials and one of the described water-soluble binders.
  • the pores are then filled with one of the described liquid pore filling materials.
  • the pore filling material is processed in the same step with the molding material and / or with the binder.
  • an organofunctional siloxane in particular sodium (3- (trihydroxysilyl) propyl) methyl phosphonate, may be added to the molding material mixture of the molding base material and the binder and optionally the pore filling material as an additive. This is particularly preferred when using one of the water glass based binders.
  • sodium nitrate and / or sodium nitrite can also be added as an additive to the organofunctional silane as well as molding mixtures with water-glass-based binder.
  • the porosity of the mold having pores produced in the first step can be adjusted, for example, via the particle size distribution of the particular particulate molding material used. For example, large particles with a largely uniform size lead to higher porosities than mixtures of large and small particles.
  • the mold has an open-pored structure.
  • the pore filling material is preferably provided in liquid form and pressed or sucked into the pores of the mold by means of pressure or underpressure.
  • a mold with an open-pored structure can be inserted into a vacuum chamber, which is subsequently evacuated.
  • the liquid pore filling material is then injected into the vacuum chamber and drawn into the pores of the mold.
  • the pore filling material is then allowed to cool until it solidifies. Thereafter, the finished shape of the vacuum chamber can be removed.
  • the pore filling material can also be introduced without pressure into the pores of the mold, in particular if it has a low viscosity.
  • the pore filling material may be provided in liquid form and the mold immersed in the liquid pore filling material, especially until it is completely covered by the pore filling material.
  • the filling of the pores with the pore filling material can also take place in several stages, in particular in two stages.
  • the selected pore filling material can after the introduction of the pore filling material into the pores upon cooling of the pore filling material, shrinkage effects occur that cause pores in the mold are not completely filled with the pore filling material.
  • the same pore filling material can be used in all these steps. However, it is in most cases expedient to use a pore-filling material in the subsequent step or steps which has a lower melting point than the pore-filling material used in the first step. Pore filling material already in the pores is then no longer melted in the subsequent step (s).
  • a mold the pores are filled with one of the pore filling materials described, usually has an extremely high storage stability, since it, even if it was made using a highly hygroscopic binder, has a high resistance to moisture, especially humidity, and thus also a high storage stability. This applies in particular if one of the stated water-insoluble materials is used as the pore filling material.
  • the treatment with the pore filling material increases the strength of the mold partly significant.
  • the molds and cores according to the invention or the molds and cores produced by the process described are preferably used for the production of fiber composite bodies or of molded plastic parts.
  • the molds and cores are also very suitable for processing concrete and ceramic materials, in particular as forms and shells for concrete and ceramic processing.
  • Some embodiments of the molds and cores are also suitable for processing liquid aluminum, in particular for die-cast aluminum.
  • the core is arranged in a mold and
  • a liquid polymer material or a liquid polymer precursor or a liquid metal is introduced.
  • the core After solidification and / or curing of the polymeric material or polymer precursor or metal, the core can be removed. However, this is not mandatory.
  • the polymeric material or polymer precursor Upon solidification and / or curing, the polymeric material or polymer precursor transforms to the plastic. It is of particular advantage in this case that penetration of the polymer material or of the polymer precursor into the pores of the mold is prevented or at least counteracted, since they are indeed filled with the pore filling material.
  • the liquid polymer material may in principle be any polymer material which can be converted into a liquid state by melting, for example a polyamide.
  • the polymer precursor can be, for example, a reactive mixture of a binder and a hardener adapted to the binder, for example a hydroxy-functional binder and an isocyanate-functional hardener (for the preparation of a polyurethane). Excellent epoxy resins and hardeners can be used as reactive mixtures.
  • the polymer material or the polymer precursor and the pore filling material are matched to one another such that the pore filling material has a melting and / or boiling point which is above the processing temperature of the polymer material or polymer precursor used, preferably at least 5 ° C., more preferably at least 20 ° C, especially at least 50 ° C.
  • the polymer material or polymer precursor used during processing does not reach temperatures exceeding said temperature difference values.
  • the processing temperature of some suitable epoxy resins is in the range of 150 ° C to 180 ° C.
  • the pore filling material used should then ideally have a melting point of at least 190 ° C, preferably of at least 200 ° C, in particular of at least 230 ° C.
  • the core may be cooled to a temperature in the range of from -20 ° C to 20 ° C prior to being contacted with the liquid polymer material or liquid polymer precursor or in the cladding with the fiber material described below , particularly preferably to a temperature in the range of - 20 ° C to 15 ° C, in particular to a temperature in the range of - 20 ° C to 10 ° C.
  • a significant increase in the hardness of the pore filling material and thus the strength of the core as a whole is brought about.
  • pore filling materials can also be used which, at temperatures above 20 ° C., make an insufficient contribution to the strength of the core.
  • the core before it is placed in the mold, preferably coated with a fiber material.
  • the fibers may be, for example, glass fibers, carbon fibers, ceramic fibers, aramid fibers, boron fibers, steel fibers, natural fibers and nylon fibers.
  • the fibers can be wrapped or braided around the core. However, it is also possible, e.g. To arrange nets, mats or fleeces from the fibers on the surface of the core.
  • the core is removed after solidification and / or curing of the polymer material or the polymer precursor by means of water and / or heating. If the pore filling material is water-soluble, the core can be removed exclusively by means of water. However, if the pore-filling material is water-repellent, the core must be converted to a water-soluble state. This is done, as already stated above, by melting the pore filling material.
  • the pore-filling material and the polymeric material or polymer precursor are preferably matched to one another such that the pore-filling material has a melting temperature which is below the melting or decomposition temperature of the plastic formed from the polymeric material or polymer precursor, preferably at least 5 ° C preferably at least 20 ° C, especially at least 50 ° C.
  • the quartz sand were placed in a laboratory paddle mixer and added with stirring the water glass and methylphosphonate. After the mixture was stirred for one minute, the amorphous silica was added with further stirring.
  • the molding material mixture was introduced by means of compressed air into a mold. To accelerate the curing of the mixture, hot air was passed through the mold. The mold was opened and the core was removed. Immediately thereafter, the core was dried.
  • colloidal silica sol Lidox HS 40, Grace Chemicals, Columbia, MD, USA
  • the quartz sand was placed in a laboratory mixer and added with stirring, the colloidal silica sol and the sodium hydroxide solution and the amorphous silica.
  • the molding material mixture was introduced by means of compressed air into a mold. To accelerate the curing of the mixture, hot air was passed through the mold. The mold was opened and the core was removed. Immediately thereafter, the core was dried.
  • the glass beads were placed in a laboratory paddle mixer and added with stirring, the di-sodium octaborate tetrahydrate and the sodium hydrogen phosphate and the water and the sodium hydroxide solution.
  • the molding material mixture was introduced by means of compressed air into a mold. To accelerate the curing of the mixture, hot air was passed through the mold. The mold was opened and the core was removed. Immediately thereafter, the core was dried.
  • the glass spheres were placed in a laboratory paddle mixer and added with stirring, the borax and Natnumhydrogenphosphat and the water and the sodium hydroxide solution.
  • the molding material mixture was introduced by means of compressed air into a mold. To accelerate the curing of the mixture, hot air was passed through the mold. The mold was opened and the core was removed. Immediately thereafter, the core was dried.
  • the glass beads were placed in a laboratory paddle mixer and added with stirring, the di-sodium octaborate tetrahydrate and Natnumhydrogenphosphat and the water and the sodium hydroxide solution.
  • the molding material mixture was introduced by means of compressed air into a mold. To accelerate the curing of the mixture, hot air was passed through the mold. The mold was opened and the core was removed. Immediately thereafter, the core was dried. Filling the pores of the cores produced according to I with a pore filling material
  • a mixture of 40 wt .-% NaN0 2 , 7 wt .-% NaNOs and 53 wt .-% KN0 3 was converted by heating in a homogeneous, low-viscosity melt.
  • cores AE produced in accordance with I. were immersed after being heated in an oven to a temperature of 140 ° C. The melt penetrated the pores of the cores and closed them. After cooling, the cores thus treated had a substantially nonporous surface.
  • a synthetic paraffin wax with a melting point of 90 ° C was converted by heating in a liquid, low viscosity state.
  • Cores A-E prepared according to I. were exposed to a vacuum in a vacuum chamber. In this chamber, the liquid paraffin was injected. The paraffin penetrated the pores of the nuclei and closed them. After cooling to room temperature and subsequent removal of the cores from the vacuum chamber, the treated cores had a substantially nonporous surface.
  • Urea was converted by heating into a homogeneous, low-viscosity melt.
  • cores A-E prepared in accordance with I. were immersed after being heated in an oven to a temperature of 140 ° C. The melt penetrated the pores of the cores and closed them. After cooling, the cores thus treated had a substantially nonporous surface.
  • Cores treated according to F and G and H and I were placed in a mold into which after closing the mold a polyamide having a processing temperature of 85 ° C was injected.
  • Cores treated according to F and G and H and I were wrapped in carbon fibers and placed in a mold into which after closing the mold a polyamide having a processing temperature of 85 ° C was injected.
  • the fiber composite body was removed from the mold.
  • the produced plastic moldings and fiber composite bodies were treated with heated to 95 ° C water. Both the cores treated according to F and G and those according to H and I could easily be removed.
  • the paraffin wax used melted as a result of contact with the water. The melted paraffin wax was then easily separated and recycled.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mold Materials And Core Materials (AREA)
  • Adhesives Or Adhesive Processes (AREA)

Abstract

La présente invention concerne un moule employé pour produire des corps composites renforcés par fibres ou des pièces moulées en métal ou en matière plastique, lequel moule se compose d'une matière de base particulaire et d'un liant, le moule présentant des pores, les pores étant remplis d'une matière de remplissage de pores, le liant étant hydrosoluble et la matière de remplissage de pores pouvant être liquéfiée par augmentation de la température et étant inerte chimiquement vis-à-vis du liant. L'invention concerne par ailleurs la production et l'utilisation du moule.
PCT/EP2016/075915 2015-11-21 2016-10-27 Moule, procédé pour le produire et son utilisation WO2017084851A1 (fr)

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EP16791348.2A EP3377289A1 (fr) 2015-11-21 2016-10-27 Moule, procédé pour le produire et son utilisation
CN201680079641.8A CN108602211A (zh) 2015-11-21 2016-10-27 模具、其制造方法和用途

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DE102015223008.2A DE102015223008A1 (de) 2015-11-21 2015-11-21 Form, Verfahren zu ihrer Herstellung und Verwendung
DE102015223008.2 2015-11-21

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DE102017223870A1 (de) 2017-12-29 2019-07-04 Audi Ag Verfahren zum Herstellen einer verlorenen Form für ein Gussbauteil und Verfahren zum Herstellen eines Gussbauteils mittels einer verlorenen Form
DE102018121847A1 (de) * 2018-09-07 2020-03-12 Hengst Se Verfahren zum Metall-Druckgießen mit verlorenem Kern
CN109773948A (zh) * 2019-03-29 2019-05-21 深圳市宏通新材料有限公司 用于陶瓷注射成型的盐模内芯材料及陶瓷制作方法
CN114917964B (zh) * 2022-06-09 2023-11-21 西安西热水务环保有限公司 一种离子交换树脂晶片材料及制备方法和应用

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