WO2020229698A1 - Procédé de production de ressorts composites et de noyau de moule pour un tel procédé - Google Patents

Procédé de production de ressorts composites et de noyau de moule pour un tel procédé Download PDF

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Publication number
WO2020229698A1
WO2020229698A1 PCT/EP2020/063780 EP2020063780W WO2020229698A1 WO 2020229698 A1 WO2020229698 A1 WO 2020229698A1 EP 2020063780 W EP2020063780 W EP 2020063780W WO 2020229698 A1 WO2020229698 A1 WO 2020229698A1
Authority
WO
WIPO (PCT)
Prior art keywords
shell
mold core
composite
negative pressure
particulate matter
Prior art date
Application number
PCT/EP2020/063780
Other languages
English (en)
Inventor
Gregor Daun
Harald Roedel
Jan Wucherpfennig
Christian Siemensen
Dirk Meckelnburg
Martin Moeller
Andreas SACHS
Wolfgang Schrof
Original Assignee
Basf Polyurethanes 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 Basf Polyurethanes Gmbh filed Critical Basf Polyurethanes Gmbh
Publication of WO2020229698A1 publication Critical patent/WO2020229698A1/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
    • B29C33/38—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
    • B29C33/3857—Manufacturing moulds, e.g. shaping the mould surface by machining by making impressions of one or more parts of models, e.g. shaped articles and including possible subsequent assembly of the parts
    • 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
    • B29C33/3821—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process composed of particles enclosed in a bag
    • 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
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/02—Bending or folding
    • B29C53/12—Bending or folding helically, e.g. for making springs
    • 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
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/80—Component parts, details or accessories; Auxiliary operations
    • B29C53/82—Cores or mandrels
    • B29C53/821—Mandrels especially adapted for winding and joining
    • B29C53/824—Mandrels especially adapted for winding and joining collapsible, e.g. elastic or inflatable; with removable parts, e.g. for regular shaped, straight tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/774—Springs
    • B29L2031/7742—Springs helical springs

Definitions

  • the invention relates to a method of producing a mold core having at least one external groove for making composite springs, in particular composite coil springs.
  • an internal mold core has been used to define at least the inner portion of the composite spring, in particular when producing composite coil springs.
  • challenges were usually present in finding efficient ways to unform the inner mold from the composite spring.
  • lost core methods were employed using casting sand or low melting alloys as mold material.
  • segmented inner support structures have been experimented with which would hold the composite wire in a radially expanded state and the segments of which could be retracted away from the composite wire, i.e. composite spring after solidification. While the quality of composite springs produced in conventional methods has been found to meet the requirements set by the industry, the manufacturing process still leaves room for improvement in terms of cost efficiency and production time.
  • the invention achieves its object by suggesting a method of producing a mold core having at least one external groove for making composite springs, in particular composite coil springs, comprising the steps of:
  • the invention is based upon the realization that by placing the particulate matter in a shell and using the filled shell as a mold core, the material which constitutes the mold core is not lost during manufacturing. Also, the solidification of the mold core by way of applying the negative pressure has the beneficial effect that the mold core is maintained in its solidified state precisely as long as the negative pressure is maintained inside the shell. Once the negative pressure is released from the shell, the mold becomes soft and deformable again, allowing for easy and fast removal of the mold from the composite spring, that is, after the mold produced in the inventive method has been provided to and used in a method of producing the coil spring itself, which is another aspect of this invention.
  • the process according to the invention provides furthermore for great flexibility regarding the type and amount of particulate matter used for forming the mold core.
  • the step of assembling the master die and the shell is conducted prior to introducing the particulate matter into the shell. Alternatively, it would also be possible to fill the shell fully or partially prior to its assembly with the master die.
  • the method comprises the step of applying a positive pressure differential between the inside of the shell and the outside of the shell, the pressure outside the shell being lower than inside the shell.
  • a positive pressure differential between the inside of the shell and the outside of the shell, the pressure outside the shell being lower than inside the shell.
  • the pressure differential is produced by applying a negative pressure on the outside of the shell, and said negative pressure on the outside of the shell is a first negative pressure, wherein the negative pressure on the inside of the shell is a second negative pressure, and furthermore, the second negative pressure is lower than the first negative pressure.
  • the shell reliably separates from the master die when the negative pressure inside the shell is applied and has reached the level predetermined as the second negative pressure level.
  • the first negative pressure is applied before the second negative pressure is applied and is released when the pressure inside the shell reaches the second negative pressure, or at least is lower than the first negative pressure.
  • Waiting to release the first negative pressure until at least some measure of negative pressure has been provided in the shell ensures that the particulate matter is solidified sufficiently so that the particulate matter retains the desired shape conforming to the shape of the master die even if the shell no longer is made to adhere to the master die by a way of the outer (first) negative pressure.
  • the step of introducing the particulate matter into the shell further comprises compacting the particulate matter by using at least one of gravity, vibration or mechanical force. Additionally, compacting the particulate matter inside the shell provides for an optimized shaping of the mold core, as the particulate matter is being firmly pushed against the shape of the master die. According to a further preferred embodiment, the step of compacting is effected by applying a mechanical compression force onto the particulate matter, preferably with a push rod from the side of the feed hole, and further preferably maintaining the compression force while the evacuation of the shell commences.
  • the particulate matter is substantially dry, meaning that no fluid is added to the particulate matter inside the shell.
  • the particulate matter is at least partially mixed with a liquid prior to or after inserting the particulate matter into the shell. The liquid preferably is configured to enhance the structural solidity of the mold core after the negative pressure has been applied.
  • the master die comprises a plurality of die segments that together define the master die, and the shape that is impressed onto the shell.
  • the master die is composed of two, three, four, or more segments.
  • a multipart master die provides the advantage of easier unforming from the mold core after applying the (second) negative pressure into the shell, in particular in cases where the shape of the mold core contains undercuts which make the mold core cling to the master die.
  • the master die comprises or consists of a polymer material, preferably produced by 3D printing. While 3D printing becomes more cost efficient and thus competitive in the industry on its own already, a particular benefit of using a 3D printed master die in the inventive application is that it obviates the need invest in master dies made from metal (which is both time consuming and cost intensive).
  • the technology eliminates or decreases the contact of the die with chemicals or heat associated with the solidification of the composite wire.
  • Composite wires that are wound around a mandrel tend to develop an axially stretched elliptical cross section. In contrast to this naturally forming shape a cross section with the shape of an axially flattened ellipse (or“egg” shape) is preferred as it tends to generate lower shear stress on the inside of the spring.
  • the core groove has a cross-sectional design that will shape the cross section of the soft spring wire into an axially flattened ellipse or slight egg shape with the sharp tip of the ellipse (or“egg”) on the inside of the coil spring.
  • the master die comprises an inside wall and at least one protrusion extending away from the wall (or several protrusions) wherein the (respective) protrusion defines the corresponding external groove in the mold core such as to give the groove a shape which produces a composite wire having an axially flattened cross section.
  • the protrusion is desired to produce a groove representative of half the thickness of the spring to be produced in the radial direction, i.e. if the groove is supposed to hold half the radial thickness of the composite wire, it would be preferred to dimension protrusion ,such that it has a height (i.e. radially with respect to a longitudinal axis of the spring to be produced) with respect to the inside wall and a width (i.e. axially with respect to the longitudinal axis of the spring to be produced), wherein preferably, the height is more than half the width
  • the“flatter” the cross section of the composite spring will be once it is produced.
  • the shell is configured to contain the particles in an air tight containment that is strong enough to hold the particles on the one hand side, while being flexible enough to adhere very closely to the shape of the master die on the other hand side.
  • the shell comprises at least one layer of a polymeric foil, said foil having a thickness in a range of 5pm to 1 mm, preferably being a thermoplastic foil having a thickness in a range of 5 pm to 50 pm or an elastomeric foil having a thickness in a range of 50 pm to 1 mm.
  • the foil has an elongation at break in a range of 10% to 200%, and further preferably a thermal stability of more than 120°C, in particular 150°C or more in hot oil. The elongation at break may preferably be measured as defined in DIN ISO 1798 or alternatively in ISO 527-3.
  • the shell comprises two or more layers of polymeric foil.
  • the layers are positioned adjacent to one another and may glide along each other. This allows the shell to be more durable even when using foil from the lower end of the spectrum of elongation capability, since stress inside the foil layers is reduced.
  • the particulate matter is configured to move into the cavity defined by the shell, fill it up to the perimeter and, preferably through a combination of form closure and force closure, form a rigid body under application of pressure. It has been found that while very small globular particles of identical size would be ideal for the particle movement whereas larger, edged particles of non-uniform size and/or shape would be ideal for forming a rigid body.
  • the particulate matter preferably comprises or consists of particles that have a bulk angle of 10° or more, preferably 20° or more, further preferred of 30° or more, in particular as defined in DIN ISO 4324 :1983-12, and/or have an aspherical surface with a particle size of 0,5 to 5 mm, preferably as defined in ISO 13320:2009-10 and/or have an uneven size distribution, and/or have a density of 3,0 g/cm 3 or less, in particular 2,9 g/cm 3 to 0,7 g/cm 3 , preferably respectively as defined in DIN EN ISO 845:2009-10, and/or have a melting temperature according to DIN 53765:1994-03 or ISO 1 1357-3:201 1 -05 of 200 °C or more; and/or have a thermal stability of more than 120°C, preferably as defined in DIN EN 1856-1 :2009- 09; and/or have a thermal conductivity of 0,02 W/(m K) or greater, further preferably 0,3 W
  • Aluminum has te advantage of having a rather high thermal conductivity in a range of more than 200 W/(m K) which benefits the curing of the composite around the mold core.
  • Other preferred materials include: polystyrene granules, in particular bulk sand, polyamide granules, for example commercially available as Ultramid ® B33 or Ultramid ® T KR 4350, or granules made of thermoplastics such as amorphous thermoplastics, for example on the basis of polyethersulfone, polysulfone and/or polyphenylsulfone, commercially available as Ultrason ® .
  • the method also relates to a method for producing a composite spring, in particular a composite coil spring, the method comprising the steps of: Providing a mold core having an external groove, providing a composite wire for the composite spring to be produced, assembling the mold core and composite wire such that the wire is disposed in the external groove of the mold core, solidifying the composite wire such that the composite spring is produced, and removing the composite spring from the mold core after a predetermined amount, preferably all, of the composite wire has solidified; wherein the step of providing the mold core encompasses the method of producing the mold core according to any one of the preferred embodiments described hereinabove under the first aspect.
  • the benefits and preferred embodiments of the first aspect are at the same time benefits and preferred embodiments of the method under the second aspect, which is reference is made to the explanations given hereinabove to avoid unnecessary repetition.
  • the composite wire is fixed to the particle filed shell core by means of an additional foil which is wound around the composite wire and the core to temporarily fix the wire to the core.
  • the method further comprises the steps of
  • the step of providing the mold core encompasses the method of producing the mold core according to any one of the preceding claims.
  • the assembly is effected as follows: i) the composite wire is assembled to the mold core;
  • the mold core is removed from the assembly prior to the step of solidifying the composite wire.
  • the method comprises the step of:
  • the method comprises the step of retaining the particulate matter in the shell after releasing the negative pressure.
  • the method comprises the step of reusing the mold core after production of the composite spring in the method of producing the mold core to any one of the preferred embodiments describe herein above to create a new mold core, wherein the step of introducing particulate matter into the shell preferably is omitted.
  • the method comprises the step of catching the particulate matter removed from the shell, preferably in a second complimentary shell, the interior which communicates with the interior of the first shell, in particular through a shell connection device that comprises at least one pressure port for applying and releasing pressure to and from the shell, respectively.
  • Fig. 1 shows a schematic representation of a method of producing a mold core according to a preferred embodiment
  • Fig. 2 shows a schematic representation of a method of producing a composite spring according to a preferred embodiment
  • Fig. 3 shows a schematic representation of a method of producing a composite spring according to a further preferred embodiment.
  • Fig. 1 schematically depicts a method 100 of producing a mold core 19 for subsequent use in a method 200, 200’ of producing a composite spring (ef. Fig. 2 and 3).
  • the method 100 comprises a method step 101 wherein a master die 1 is provided.
  • the master die 1 comprises a number of protrusions 5 inside a cavity 3.
  • the cavity 3 defines a negative shape of the mold core 19 to be produced.
  • the master die 1 is formed as a multipart die and comprises a first die segment 1 a and at least a second die segment 1 b.
  • the master die 1 may comprise more than two segments.
  • the master die 1 comprises at least one evacuation port 7 for withdrawing air from the cavity 3.
  • a shell 9 is provided and introduced into the master die 1 .
  • the shell 9 comprises a feed hole 1 1 for introduction of particular material 13.
  • a first negative pressure NP1 is applied in between the outside of the shell 9 and the master die 1 , as a consequence of which the shell 9 adopts the shape of the cavity 3.
  • step 107 the particulate matter 13 is introduced into the shell 9 through the feed hole 1 1 .
  • Steps 105 and 107 may also be conducted in reverse order, in which in step 105’ the shell would be pre-filled with particulate matter 13 and then introduced into the master die 1 , or be filled with particulate matter 13 after having been introduced into the master die 1 in step 103.
  • the negative pressure NP1 would be applied afterwards in step 107’.
  • the particulate matter 13 After the particulate matter 13 has been introduced into the shell 9, and the first negative pressure NP1 has been applied, the particulate matter 13 preferably is compacted in a next method step 109 by applying mechanical force onto the particulate matter 13 with a push rod 15.
  • the push rod 15 comprises an evacuation port 17 for withdrawing air from the inside of the shell 9.
  • step 1 1 1 a second negative pressure NP2 is applied inside the shell 9, leading to a solidification of the particulate matter 13.
  • the predetermined negative pressure NP2 is reached, or is at least lower than the first negative pressure NP1 , the first negative pressure NP1 may be released.
  • the particulate matter 13 will maintain its shape due to the application of the second negative pressure NP2 and the mold core 19 has been produced.
  • the master die 1 While maintaining the second negative pressure NP2, the master die 1 is then removed in a next method step 1 13, and the mold core 19 may be provided in a method 200, 200’ of producing the composite spring, as is exemplarily described in the ensuing figures 2 and 3.
  • Fig. 2 exemplarily shows a first preferred embodiment of producing a composite spring with a mold core 19 as obtained in the method 100 shown in Fig. 1 .
  • step 201 the mold core 19 obtained in method 100 is provided.
  • step 203 a composite wire 21 for producing the composite spring is provided.
  • step 205 the composite wire 21 is wound around the mold core 19.
  • step 207 the composite wire 21 is solidified, for example by applying energy with an energy source 23. After the composite wire 21 has solidified to a predetermined sufficient rate, the particulate matter 13 inside the shell 9 is softened by releasing the negative pressure NP2 maintained previously inside the shell 9, and what previously was the mold core 19 can easily be removed from the assembly. This is shown in step 209.
  • the composite spring is obtained.
  • a step 213 the still particle-filled shell 9 is reused in the method 100 for producing the mold core 19 anew by placing the shell 9 inside the master die 1 again.
  • the shell 9 is made to adopt the shape of the master die 1 , and the particulate matter 13 is solidified to obtain once again the mold core 19 which can then be provided for another round of producing a composite spring in the method 200.
  • an external mold 25 may be employed, which is shown in Fig. 3 with exemplary preferred method 200’.
  • Method 200’ is largely similar to method 200.
  • an external mold 25 is provided in step 202.
  • the pre-assembly of mold core 19 and composite wire 21 is assembled in step 205” with the external mold 25 such that the composite wire 21 is disposed within a volume between the mold core 19 and the external mold 25.
  • step 207’ the solidification of the composite wire 21 is carried out in step 207’ with both the mold core 19 and the external mold 25 being assembled.
  • step 208 the negative pressure inside the shell 9 is released at the particulate matter 13 softened.
  • step 209’ the shell 9, still filled with particulate matter 13, can easily be removed from the composite wire 21 and external mold 25. If the solidification process according to step 207’ has already taken place, the composite spring would now be obtained.
  • the composite spring After removing the composite wire 21 from the external mold 25, in method step 21 1 , the composite spring can be withdrawn from the procedure, while in method step 215, the external mold 215 can be reused in the method 200’ for producing the next composite spring.
  • the shell 9 filled with particulate matter 13 may be reused in method step 213 to reproduce the mold core 19.
  • One advantage of removing the particulate matter from the external mold 25 prior to the solidification step 207” is that the particulate matter 13 is not subjected to the solidification energy, e.g. high temperatures, which increases the longevity of the shell 9 and the particulate matter 13.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

L'invention concerne un procédé de production d'un noyau de moule (19) ayant au moins une rainure externe pour fabriquer des ressorts composites, en particulier des ressorts hélicoïdaux composites, comprenant les étapes consistant à fournir une matrice maître (1), la matrice maître (1) ayant une forme interne qui définit une forme négative du noyau de moule (19), fournir une coque souple étanche aux gaz (9) ayant au moins une ouverture d'alimentation (11), étendre la coque par l'introduction de matière particulaire non liée (13) dans la coque (9) à travers l'ouverture d'alimentation (11), assembler la matrice maître (1) et la coque (9) de telle sorte que la matrice maître (1) enferme la coque (9) et la matière particulaire (13) amène la coque (9) à prendre une forme négative de la matrice maître (1), et solidifier la forme de la coque (9) par application d'une pression négative à l'intérieur de la coque (9), de manière à obtenir le noyau de moule (19).
PCT/EP2020/063780 2019-05-16 2020-05-18 Procédé de production de ressorts composites et de noyau de moule pour un tel procédé WO2020229698A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP19174994.4 2019-05-16
EP19174994 2019-05-16

Publications (1)

Publication Number Publication Date
WO2020229698A1 true WO2020229698A1 (fr) 2020-11-19

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022161754A1 (fr) * 2021-01-26 2022-08-04 Basf Polyurethanes Gmbh Pièce coulée plus grande que le moule de coulée

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4260143A (en) * 1979-01-15 1981-04-07 Celanese Corporation Carbon fiber reinforced composite coil spring
US4473217A (en) * 1982-01-07 1984-09-25 Kato Hatsujo Kaisha, Limited Fiber-reinforced resin coil spring and method of manufacturing the same
DE8711336U1 (de) * 1987-08-20 1987-10-22 Ems-Inventa AG, Zürich Formkern zur Herstellung von Hohlkörpern
US20090309268A1 (en) * 2006-03-20 2009-12-17 Eads France Method for producing structures of complex shapes of composite materials
WO2019020703A1 (fr) * 2017-07-25 2019-01-31 Basf Se Procédé de fabrication d'un ressort hélicoïdal

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4260143A (en) * 1979-01-15 1981-04-07 Celanese Corporation Carbon fiber reinforced composite coil spring
US4473217A (en) * 1982-01-07 1984-09-25 Kato Hatsujo Kaisha, Limited Fiber-reinforced resin coil spring and method of manufacturing the same
DE8711336U1 (de) * 1987-08-20 1987-10-22 Ems-Inventa AG, Zürich Formkern zur Herstellung von Hohlkörpern
US20090309268A1 (en) * 2006-03-20 2009-12-17 Eads France Method for producing structures of complex shapes of composite materials
WO2019020703A1 (fr) * 2017-07-25 2019-01-31 Basf Se Procédé de fabrication d'un ressort hélicoïdal

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022161754A1 (fr) * 2021-01-26 2022-08-04 Basf Polyurethanes Gmbh Pièce coulée plus grande que le moule de coulée

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