WO2021074004A1

WO2021074004A1 - Method for producing a composite component with a flawless surface

Info

Publication number: WO2021074004A1
Application number: PCT/EP2020/078268
Authority: WO
Inventors: Oliver Schulz; Ulrich Grosser; Thorsten Schulz
Original assignee: Covestro Intellectual Property Gmbh & Co. Kg
Priority date: 2019-10-15
Filing date: 2020-10-08
Publication date: 2021-04-22

Abstract

The subject matter of the present invention concerns a method for shaping a semifinished product (1) from a thermoplastic polymeric fibre-composite material in an injection-moulding machine, comprising the following steps: a) heating the semifinished product in a heating device (3) to at least the glass transition temperature Tg or the melting temperature TS of the polymer matrix of the thermoplastic polymeric fibre-composite material and gripping the semifinished product with a gripping device (2) in at least an edge region of the semifinished product (1) and transferring the semifinished product (1) into a shaping mould (4) with at least two, first and second, contour parts (5, 6), which correspond to one another, have moulding surfaces facing one another and are movable along a longitudinal axis in the horizontal direction in relation to one another, wherein the semifinished product (1) is introduced between the contour parts (5, 6) in such a way that, at least in the edge region that is being held, the semifinished product (1) protrudes beyond the edge of the moulding surfaces and forms a projection, b) moving the contour parts (5, 6) together and shaping the semifinished product (1), which, just before contact with the moulding surfaces, is at least at the glass transition temperature Tg or the melting temperature TS of the polymer matrix of the thermoplastic polymeric fibre-composite material, c) releasing and withdrawing the gripping device (2) from the region of the contour parts (5, 6), and d) moving an edge-working device (9), which is held on the outer side of at least the first contour part in such a way that it can be displaced in the closing direction of the shaping mould (4), at least over the previous holding region of the gripping device (2), wherein the projection is crimped and/or cut off, at least in the edge region that is being held, e) introducing moulding material onto, around or behind the shaped semifinished product, wherein steps a) to e) are only carried out in this one shaping mould. The invention also relates to a shaped semifinished product obtainable by the method and to the use thereof and to a device for carrying out the method.

Description

Process for the production of a composite component with an undisturbed surface

The subject matter of the present invention relates to a method for reshaping a semifinished product made from a thermoplastic polymer fiber composite material and a device for carrying out this method. The invention also relates to a formed semifinished product obtainable by the method and its use.

Such methods are known from the prior art. DE 102007009384 A1, for example, discloses the forming and back injection molding of a foam film on an injection molding machine. The film is heated and positioned between the mold halves and reshaped by the closing movement of the mold. For this purpose, a clamping frame clamps the film around the edge or a device is used that allows the film to slide down.

DE 102010053381 A1 discloses common methods for producing a composite component using an injection molding machine and using a deep-drawing tool and injection molding machine. After heating, the semi-finished product is held in the forming tool with fixing pins prior to forming.

In order to ensure that the semifinished product is fixed during the forming process, WO 201350026 A1 proposes the use of retaining pins in the tool. It is also possible to inject the formed semi-finished product in the forming tool.

EP 3216578 A1 describes an injection molding tool with gripper elements on both sides integrated in a cavity. A semi-finished product made of fiber-reinforced plastic is held by this, reshaped by the closing movement of the injection molding tool and back-injected. One-sided or two-sided slide elements for pre-draping and / or fixing in the tool within the tool cavity are also proposed in WO 19049084 A1.

EP2524796A1 discloses a method for producing an essentially shell-shaped plastic part. Because one of the two shaping matrices is movable relative to the forming tool, the disadvantage of processing semi-finished products made of thermoplastic polymer fiber composite material is that not the entire locking force of the injection molding machine can be applied to the semi-finished product when the semi-finished product is transferred.

DE102014217173A1 discloses an injection molding machine and a method for producing molded parts with this machine. The edge of the molded part is trimmed by the forming tool during and before the end of the forming process. This has the disadvantage that the trimmed semi-finished product is withdrawn in the direction of the center of the tool as the deformation progresses and an uneven edge is thus formed. DE102013222357A1 discloses a molding tool and a method for processing a fiber composite component. The molding tool has at least one clamping device for locally compressing the fiber composite component.

Although the use of the tool-side grippers or fixing elements known from the prior art enables precise and efficient handling of the semi-finished product to be formed, the pressure exerted by the gripper elements results in undesirable surface markings on the molded part made of thermoplastic fiber composite material. In the case of the two-sided gripper, by imprinting a deformation on the visible side. In addition, the usually metallic grippers lead to heat dissipation in the grip area. This can also be perceived as disadvantageous, because as a result it is often not possible to ensure that the tool surface is adequately molded.

task

Based on this state of the art, the object of the present invention was to provide a method and a device for reshaping a semi-finished product made of a thermoplastic polymer fiber composite material which, on the one hand, enables precise handling of the semi-finished products to be formed and formed components with simultaneously high production cycle rates, but at the same time enables The formation of marks caused by gripping devices is prevented. The method according to the invention should manage in the tool cavity of the forming tool without fixing pins, holding pins, alternatively fixing points such as openings or the like, one-sided or two-sided slide elements, clamping devices for locally compressing the fiber composite semi-finished product in order to prevent the formation of fixing pins, holding pins, alternatively fixing points such as openings or the like, to avoid unilateral or bilateral slide elements, or clamping devices caused imprints or other undesirable surface markings on the molded part produced. The method should preferably be suitable for carrying out on a conventional injection molding machine so that further elements can be applied to the semi-finished product in the same forming tool, such as by injection molding on, around and / or back molding.

solution

The object is achieved in a generic method by a method for reshaping a semi-finished product made of a thermoplastic polymer fiber composite material in an injection molding machine, comprising the following steps a) heating the semi-finished product in a heating device to at least the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material and gripping the semifinished product with a gripping device in at least one edge region of the semifinished product and placing the semifinished product in a forming tool with at least two first and second contour parts that are movable relative to one another on a longitudinal axis and correspond to one another and have mutually facing mold surfaces, the semifinished product in the manner is introduced between the contour parts that the semi-finished product protrudes at least in the edge area held over the edge of the mold and forms a protrusion, b) moving the contour parts together and reshaping the semi-finished product, which immediately before contact with the mold surfaces at least the glass transition temperature T _g or the Having melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material, c) releasing and moving the gripping device out of the area of the contour parts, and d) moving one on the outside of at least the first con part of the edge processing device held displaceably in the closing direction of the forming tool at least over the previous holding area of the gripping device, the protrusion being flanged and / or cut off at least in the held edge area, e) injection molding on, around and / or back-molding of the formed semi-finished product, whereby the Steps a) to e) are carried out in just this one forming tool.

The injection molding on, around and / or back molding of the formed semi-finished product can be used, for example, to apply further elements.

The present invention is based on the knowledge that a gripping device is used in the method according to the invention in such a way that the semi-finished product can be fixed practically over the entire shaping process, but the holding points of the gripping device lie outside the primary forming area and this area further Process is removed by cutting or flanging or optically concealed in such a way that no breakpoints are visible on the finished formed component in the primary field of vision. In addition, this makes it possible to apply the entire locking force of the injection molding machine to the forming tool or the semifinished product when the semifinished product is transferred.

The forming tool is designed in such a way that there is a direct flow of force between the injection molding machine and the contour parts of the forming tool and thus the high pressure required for forming and consolidation can be applied to the inserted semi-finished product via the contour parts. This is preferred according to the invention. The forming tool is also designed in such a way that the tool cavity of the forming tool does not have any fixing pins, holding pins, clamping devices and / or slide elements on one or both sides.

This enables the surface of the contour insert to be molded as precisely as possible and a uniform consolidation of the semifinished product, which is relevant for a high quality and uniform appearance of the finished component.

In the context of the present invention, the statement that it is possible “to apply the entire locking force of the injection molding machine to the semi-finished product when transferring the semifinished product” is to be understood in particular as meaning that in step (b) at least 90% of the maximum achievable locking force of the injection molding machine within of five (5) seconds or less, preferably within three (3) seconds or less, particularly preferably within one (1) second or less, very particularly preferably in half a second or less after the forming tool has been completely brought together onto the semifinished product is applied. According to the invention, in step (b) at least 95% of the maximum achievable locking force of the forming tool is very particularly preferably applied to the semifinished product within half a second or less after the forming tool has been completely brought together.

According to the invention, it is also preferred that the corresponding first and second contour parts are only connected to the injection molding machine by rigid connections, which makes it possible to apply such a high locking force to the semi-finished product within such a short time.

Another advantage of the method according to the invention is that the method steps can be carried out on a conventional injection molding machine. In other words, the processor, who otherwise processes already formed semi-finished products and provides them with on, overmoulding or back injection, can carry out the process steps of forming and on, around and / or back injection in one operation on his injection molding machine.

When the method is used on an injection molding machine, the longitudinal axis of the first and second contour parts, which are movable relative to one another and correspond to one another, are preferably aligned essentially horizontally.

Another advantage is that, in conventional forming processes, the edge of a formed component often has a contour with large tolerances, which is perceived as disadvantageous depending on the application. In the method according to the invention, however, the component is flanged or cut off at the edge after the deformation, whereby an edge that is true to the contour is obtained. When forming and encapsulating a semifinished product in one operation according to the methods known up to now in the prior art, an edge true to the contour is created, which is formed by the back injection material. The transition between the semi-finished product and the back injection material is often clearly visible. In addition, due to the large tolerance of the edge of the semi-finished product after reshaping, the molded edge is not uniformly wide, which is perceived as disadvantageous depending on the application. Alternatively, the reshaped semi-finished product would have to be trimmed in an intermediate step and then placed again in an injection molding machine for back injection, which, however, is complex and can also be at the expense of manufacturing precision.

According to the invention, the semifinished product is heated in step a) to at least the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material. In this case, heating to at least the glass transition temperature T _g, in particular in the case of amorphous thermoplastics, and heating to the melting temperature Ts, in particular in the case of (partially) crystalline polymer matrices, is provided. In the case of (partially) crystalline polymer matrices, the heating is preferably carried out to 0 to 100 ° C. above T _s , preferably to 20 to 50 ° C. above T _s . In the case of amorphous polymer matrices, the heating takes place preferably to 0 to 220 ° C. above T _g , more preferably to 50-220 ° C. above T _g , particularly preferably to 100-210 ° C. above T _g .

In the context of the present invention, the term “flanging” is understood to mean that at least a portion of the protruding edge of the semifinished product made of a thermoplastic polymer fiber composite material is reshaped by the displaceably held edge processing device. The deformation angle is preferably in the range from> 0 ° to 90 °, more preferably 20 ° or more, even more preferably 45 ° or more, particularly preferably in the range 60 ° to 90 °. The angle is typically determined by the structural design of the edge processing device and its contour-forming surface.

The width of the edge area gripped in step a) can in principle be freely selected, the width preferably being less than 20 mm, more preferably less than 10 mm, particularly preferably less than 5 mm.

In step a) of the method according to the invention, the heating and gripping of the semifinished product can take place in any order or at the same time. The semifinished product is preferably gripped first and then heated.

In the method according to the invention, the formed semifinished product can have a temperature of at least the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material during flanging. Through this the polymer matrix still has sufficient deformability. The temperature to be set for this is different from polymer to polymer and still depends on the possible Additi vation by plasticizers and the like. The temperature can be determined with a few test runs. The glass transition temperature of the polymer matrix can take place, for example, by means of DSC measurement, as specified in DIN EN ISO 11357-2: 2014-07, or by means of DMA in accordance with DIN EN ISO 6721-1: 2019-09. In the case of (partially) crystalline polymers, the heating preferably takes place at least up to the melting temperature Ts of the polymer matrix. The melting temperature Ts can be determined, for example, in accordance with DIN EN ISO 11357-3: 2013-04.

The edge processing device can be constructed as a continuous frame or else from several individually or jointly displaceable segments. The edge processing device can be designed in such a way that it is designed in partial areas for flanging and in other partial areas for severing the protrusion.

When the protrusion is flanged or severed, the reshaped semi-finished product can have a temperature below, equal to or above the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material. However, it is preferred that, during flanging, the reshaped semi-finished product has a temperature above the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material.

In order to prevent the temperature of the semifinished product from dropping so sharply when the edge area is flanged that there is insufficient deformability, the shape-forming contour in the area of the edge to be deformed can be heated by means of variothermal or dynamic temperature control in such a way that deformation is possible. The forming tool is kept at a high temperature during the forming and the flanging, the polymer matrix of the thermoplastic polymer composite material having at least the glass transition temperature T _g or the melting temperature Ts, and only then cooled to enable the component to be removed from the mold. Optionally, the forming tool can also only be cooled after the back injection phase.

The method according to the invention can be designed in such a way that the first contour part is movable on the horizontal longitudinal axis of the injection molding machine and the second contour part is static.

Advantageously, in step c) the gripping device is moved out of the area of the contour parts at least so far that the edge processing device does not collide with the gripping device during the movement. As stated at the outset, the method according to the invention can be carried out on an injection molding machine. This fact can be used to the effect that, apart from the forming process, components can be injected, encapsulated and / or back-injected directly onto the formed component in one operation. Thus, at least one channel-like melt feed line can be formed in at least one of the contour parts, which opens into the molding surface of this contour part, with the formed semi-finished product being injected with a thermoplastic polymer through this melt feed line on the side facing this contour part during or after the forming with closed contour parts. During the injection process, the semifinished product can have a temperature below, equal to or above the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material, with the thermoplastic polymer to be injected and the semifinished product preferably at a temperature of at least the glass transition temperature during the injection process T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material. With this choice of temperature, on the one hand, a firm bond between the different components can be ensured and, on the other hand, thermal stresses between the components can be avoided.

It can further be provided that when the edge processing device is moved, when the end position is reached, a cavity is formed between the edge processing device and the second contour part, which is in fluid connection with a melt feed line running through the second contour part and has contact, bypass and / or injection molding of the beaded overhang with a thermoplastic polymer, the thermoplastic polymer to be injected and the semi-finished product preferably at a temperature of at least the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material during the injection molding process exhibit. By molding on, overmolding or back molding, for example, precise edge molding can be carried out or various functional elements can be attached, such as ribs, screw domes, snap hooks, molded metal inserts, guide elements, decorative elements or housing elements.

If the edge is not sheared off and injected on, around and / or behind, it is advantageous if the flanging takes place before the on, around and / or back injection, since in this case the amount of heat dissipated is less until the forming, which is advantageous for the reshaping of the edge area. The flanging should take place immediately and as quickly as possible after the shaping of the semifinished product, since otherwise the polymer matrix could solidify, so that no further shaping would be possible. The back injection can take place after forming or at the same time. If the beaded edge area is not injected onto, around and / or back-molded, the beading and the Back-injected also take place at the same time. This is advantageous because the amount of heat dissipated up to the back injection is lower and the adhesion of the back injection material to the formed semi-finished product is positively influenced. Among other things, if the flanging and / or severing takes place separately from the on, over and / or back molding, a variothermal or dynamic temperature control of one, preferably both, contour parts, if desired also in partial areas, or alternatively of interchangeable inserts in the contour parts take place, preferably to a temperature of at least the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material. As a result, the amount of heat dissipated from the semi-finished product can be kept low in all steps, so that both the deformability during the forming of the semi-finished product, the flanging of the edge and the adhesion of the thermoplastic polymer injected onto, around and / or back-injected are positively influenced.

In the above-mentioned configurations, the thermoplastic polymer used for molding on, around and / or back molding can be selected to be identical to or different from the thermoplastic polymer of the semifinished product.

_{The semifinished product can be cooled to below the glass transition temperature T g} or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material and then removed from the mold after reshaping and, if appropriate, injection molding on, around and / or back molding.

The polymer matrix of the thermoplastic polymer fiber composite material can be selected from all materials known to the person skilled in the art. Polycarbonate (PC) or its blends, in particular with acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile copolymer (SAN), polyethylene terephthalate (PET) and / or polybutylene terephthalate (PBT), polymethyl methacrylate (PMMA) are preferred in the context of the present invention ), Polyphenylene sulfide (PPS), polyamide (PA), polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), polyetheretherketone (PEEK), polyaryletherketone (PAEK), thermoplastic polyurethane (TPU), acrylonitrile butadiene styrene (ABS ), Styrene-acrylonitrile copolymer (SAN), polyethylene terephthalate (PET), polybutylene terephthalate (PBT) or mixtures (blends) of these, with polycarbonate (PC) and its blends and thermoplastic polyurethane (TPU) being particularly preferred.

Glass, polymer, in particular aramid or Kevlar fibers, carbon fibers and natural fibers, preferably made of glass and carbon fibers, are preferably suitable as fiber reinforcement of the thermoplastic polymer fiber composite material, the fibers preferably being continuous fibers. The fiber reinforcement of the thermoplastic polymer fiber composite material can be present, for example, as a laid, knitted fabric, woven, fleece, mat, knitted fabric, mesh, unidirectional fiber layer or combinations thereof. Another object of the present invention relates to a shaped semi-finished product that can be obtained by a method according to the invention.

The invention also relates to the use of a formed semifinished product according to the invention in the automotive sector, in particular in visible and structural components, for example hubcaps, center console cladding, headrests, hat racks, door handles, pillar cladding, spoilers, door sills, mirror covers, radiator grilles, front grilles, fan blades, in luggage, for example in Suitcases, in furniture, for example in chairs, tables, cupboards, in particular for furniture in vehicles, for example in mobile homes or caravans, in or on bicycles, for example on e-bikes, racing bikes, mountain bikes, gravel bikes, city bikes, as Structural components on bicycles, for example frames, forks, handlebars, as add-on parts, for example as saddles, seat posts, mountings, springs, cranks, and in sports equipment, for example for hockey, tennis, football, rugby, as rackets, helmets, protective equipment, shin guards, Arm protectors, skis, ski boots, wakeboards, surfboards, Paddles, diving fins and generally as reinforcement elements in clothing, for example shoe soles, in electronic devices, for example drones, monitors, tablets, mobile phones, laptops or computers, especially in a laptop, or in housing parts that are suitable for use as or for use in a housing of an electronic device, in medical devices, for example orthotics, prostheses, in household devices, as equipment for aircraft and rail vehicles.

The invention also relates to a device for reshaping a semi-finished product made from a thermoplastic polymer fiber composite material comprising an optional heating device for heating the semi-finished product to at least the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material and a movable gripping device for gripping the semi-finished product to be reshaped at least an edge area of the semifinished product, the gripping device allowing the semifinished product to be moved into a forming tool with at least two first and second contour parts that are movable on a longitudinal axis and corresponding to one another with facing mold surfaces and the semifinished product can be introduced between the contour parts with the gripping device is that this project at least in the held edge area over the edge of the mold and can form a protrusion, the contour parts for reshaping d semifinished product can be moved towards one another, and on the outside of at least the first contour part an edge processing device is provided, which is held displaceably in the closing direction of the forming tool at least over the holding area of the gripping device and is suitable for flanging or cutting off the excess. According to the invention, the forming tool preferably has two first and second contour parts which are movable relative to one another on a horizontal longitudinal axis and which correspond to one another.

The forming tool is also designed in such a way that the tool cavity of the forming tool does not have any fixing pins, holding pins, clamping devices and / or slide elements on one or both sides.

A surface structure, such as, for example, high gloss, fine grain, leather grain and the like, can be introduced into the forming tool in sections or over the entire surface. For better shaping of the surface structure, one, preferably both, contour parts, if desired also in partial areas, or alternatively possible interchangeable inserts introduced into the contour parts, can be variothermally or dynamically tempered, preferably to a temperature of at least the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material until the semifinished product has been completely reshaped and the tool surface has been shaped and optionally injected onto and / or back-molded. The temperature of the contour parts, the partial areas or the interchangeable inserts can then be reduced again as quickly as possible in order to enable the component produced to be removed from the mold quickly. If polycarbonate is used as the polymer matrix of the thermoplastic polymer fiber composite material, the surface temperature of the contour part, the partial areas or the interchangeable inserts is preferably at least 20 ° C above the T _g , preferably 20 to 60 ° C above the T _{g of} the polymer matrix.

According to the invention, the forming tool is designed as an injection molding tool, or is assigned to a part of an injection molding machine or an injection molding machine.

In a further embodiment, the forming tool is designed, for example, as a reversible plate tool, index plate tool, turntable tool, sliding table tool or cube tool.

According to a further preferred embodiment of the device according to the invention, the contour parts in the region of the mold surfaces do not have any fixing elements for the semi-finished product to be formed, such as pins and the like, for example. The semi-finished product is therefore not taken over by the tool using the fixing elements usually provided for this purpose, but rather over the entire shaped surface of the contoured parts. The fixation of the semifinished product up to the takeover of the semifinished product by the mold surfaces thus takes place essentially exclusively by the movable gripping device.

The invention relates in particular to the following embodiments: According to a first embodiment, the invention relates to a method for reshaping a semi-finished product 1 made of a thermoplastic polymer fiber composite material in an injection molding machine, comprising the following steps a) heating the semi-finished product in a heating device 3 to at least the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material and gripping the semifinished product with a gripping device 2 in at least one edge area of the semifinished product 1 and placing the semifinished product 1 in a forming tool 4 with at least two first and second contour parts 5, 6 that are movable relative to one another in a horizontal direction on a longitudinal axis and correspond to one another facing mold surfaces, the semifinished product 1 being introduced between the contour parts 5, 6 in such a way that the semifinished product 1 protrudes over the edge of the mold surfaces at least in the held edge area and forms a protrusion, b) moving the contour parts 5, 6 together and reshaping the semi-finished product 1, which immediately before contact with the mold surfaces has at least the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material, c) releasing and extending the gripping device 2 from the area of the contour parts 5, 6, as well as d) the method of an edge processing device 9, held displaceably on the outside of at least the first contour part in the closing direction of the forming tool 4, at least over the previous holding area of the gripping device 2, the protrusion being beaded at least in the held edge area and / or is separated, e) injection molding on, around and / or back molding of the formed semifinished product, steps a) to e) being carried out in only this one forming tool.

According to the invention, it is also preferred that the first contour part 5 is movable on the longitudinal axis of the injection molding machine and the second contour part 6 is static.

According to a second embodiment, the invention relates to a method according to embodiment 1, characterized in that in step (b) at least 90% of the maximum achievable locking force of the injection molding machine within five (5) seconds or less, preferably within three (3) seconds or less less, particularly preferably within one (1) second or less, very particularly preferably within half a second or less, after the forming tool has been completely brought together, is applied to the semifinished product. According to the invention, at least 95% of the maximum achievable locking force of the injection molding machine within half a second is very particularly preferred in step (b) less applied to the semifinished product after the forming tool has been brought together completely.

According to a third embodiment, the invention relates to a method according to embodiment

1 or embodiment 2, characterized in that the reshaped semi-finished product 1 has a temperature of at least the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material after flanging or cutting off the protrusion.

According to a fourth embodiment, the invention relates to a method according to one of the preceding embodiments, characterized in that the reshaped semi-finished product 1 has a temperature below the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material after separating the protrusion.

According to a fifth embodiment, the invention relates to a method according to one of the preceding embodiments, characterized in that the edge processing device 9 is designed as a continuous frame or is made up of several individually or jointly displaceable segments.

According to a sixth embodiment, the invention relates to a method according to embodiment 5, characterized in that the segments of the edge processing device 9 are designed in part for flanging and in part for severing the protrusion.

According to a seventh embodiment, the invention relates to a method according to one of the preceding embodiments, characterized in that in step c the gripping device

2 is moved out of the area of the contour parts 5, 6 at least so far that the edge processing device 9 does not collide with the gripping device 2 during the movement.

According to an eighth embodiment, the invention relates to a method according to one of the preceding embodiments, characterized in that at least one melt feed line 7 is formed in at least one of the contour parts 5, 6, which opens into the molding surface of this contour part, the formed semi-finished product 1 through this melt feed line 7 on the side facing precisely this contour part 5 during or after the forming with closed contour parts 5, 6 is injection molded with a thermoplastic polymer, the thermoplastic polymer to be injected and the semi-finished product 1 preferably at a temperature of at least the glass transition temperature T _g or the during the injection molding process Have melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material. According to a ninth embodiment, the invention relates to a method according to one of the preceding embodiments, characterized in that in the method of

Edge processing device 9 when the end position is reached between the edge processing device 9 and the second contour part 6, a cavity is formed which is in fluid connection with a melt feed line 7 running through the second contour part 6 and injection-molding around, around and / or back of the beaded Supernatant with a thermoplastic polymer, the thermoplastic polymer to be injected and the semifinished product 1 preferably having a temperature of at least the during the injection molding process, around molding and / or back molding

Glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material.

According to a tenth embodiment, the invention relates to a method according to embodiment 8 or 9, characterized in that the thermoplastic polymer used for injection molding on, around and / or back molding is identical to or different from the thermoplastic polymer of the semifinished product 1.

According to an eleventh embodiment, the invention relates to a method according to one of the preceding embodiments, characterized in that the semifinished product 1 after forming and optionally molding on, around and / or back molding below the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite is cooled and then removed from the mold.

According to a twelfth embodiment, the invention relates to a method according to one of the preceding embodiments, characterized in that the polymer matrix of the thermoplastic polymer fiber composite material is selected from polycarbonate (PC) or its blends, in particular with acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile -Copolymer (SAN), polyethylene terephthalate (PET) and / or polybutylene terephthalate (PBT), polymethyl methacrylate (PMMA), polyphenylene sulfide (PPS), polyamide (PA), polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), polyether ether ketone ( PEEK), polyaryletherketone (PAEK), thermoplastic polyurethane (TPU), acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile copolymer (SAN), polyethylene terephthalate (PET), polybutylene terephthalate (PBT) or mixtures of these, with polycarbonate (PC ) and its blends and thermoplastic polyurethane (TPU) are particularly preferred.

According to a thirteenth embodiment, the invention relates to a method according to one of the preceding embodiments, characterized in that the fiber reinforcement of the thermoplastic polymer fiber composite material is selected from glass, polymer, in particular aramid or Kevlar fibers, carbon fibers and natural fibers, preferably from Glass and carbon fibers, the fibers preferably being continuous fibers. According to a fourteenth embodiment, the invention relates to a method according to one of the preceding embodiments, characterized in that the fiber reinforcement of the thermoplastic polymer fiber composite material is selected from scrim, knitted fabric, woven fabric, fleece, mat, knitted fabric, braid, unidirectional fiber layer or combinations thereof.

According to a fifteenth embodiment, the invention relates to a method according to one of the preceding embodiments, characterized in that the forming tool is designed such that the tool cavity of the forming tool does not have any fixing pins, retaining pins, clamping devices and / or slide elements on one or both sides.

According to a sixteenth embodiment, the invention relates to a formed semifinished product 1, obtainable by a method according to one of embodiments 1 to 15.

According to a seventeenth embodiment, the invention relates to the use of a formed semi-finished product 1 according to embodiment 16 in the automotive sector, in particular in visible and structural components, preferably wheel caps, center console trim, headrests, hat racks, door handles, pillar trim, spoilers, door sills, mirror covers, radiator grilles, front grilles, fan blades , in luggage, preferably in suitcases, in furniture, preferably in chairs, tables, cupboards, especially for furniture in vehicles, preferably in mobile homes or caravans, in or on bicycles, preferably on e-bikes, racing bikes, mountain bikes, gravel bikes , City bikes, as structural components on bicycles, preferably frames, forks, handlebars, as add-on parts, preferably as saddles, seat posts, mountings, springs, cranks, and in sports equipment, preferably for hockey, tennis, football, rugby, as rackets, Helmets, protective equipment, shin guards, arm guards, skis, ski boots, Wakeboards, surfboards, paddles, diving fins and generally as reinforcement elements in clothing, preferably shoe soles, in electronic devices, preferably drones, monitors, tablets, mobile phones, laptops or computers, especially in a laptop, or in housing parts that are suitable for use as or use in a housing of an electronic device, in medical devices, preferably orthotics, prostheses, in household devices, as equipment for aircraft and rail vehicles.

According to an eighteenth embodiment, the invention relates to a device for reshaping a semifinished product 1 made of a thermoplastic polymer fiber composite material comprising an optional heating device 3 for heating the semifinished product 1 to at least the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material and a movable gripping device 2 for gripping the semifinished product 1 to be formed in at least one edge region of the semifinished product 1, the gripping device 2 also moving the semifinished product 1 into a forming tool 4 at least two first and second contour parts 5, 6 with mutually facing mold surfaces, which are movable relative to one another in a horizontal direction and correspond to one another, and the semi-finished product 1 with the gripping device 2 can be introduced between the contour parts 5, 6 in such a way that this is at least can protrude beyond the edge of the shaping surfaces in the held edge area and form a protrusion, the contour parts 5, 6 being able to be moved towards one another for shaping the semi-finished product 1, and on the outside of at least the first contour part 5 one in the closing direction of the shaping tool 4 at least over the Holding area of the gripping device 2 displaceably held edge processing device 9 is provided, which is suitable for flanging or cutting off the excess.

According to a nineteenth embodiment, the invention relates to a device according to embodiment 18, characterized in that the forming tool is designed in such a way that the tool cavity of the forming tool does not have any fixing pins, retaining pins, clamping devices and / or slide elements on one or both sides.

According to a nineteenth embodiment, the invention relates to a device according to embodiment 18 or 19, characterized in that the forming tool 4 is designed as an injection molding tool or is part of an injection molding machine or is assigned to such a machine.

The invention is illustrated below with reference to FIGS. 1 to 4 explained in more detail. 1 shows a first embodiment of the method according to the invention,

FIG. 2 shows two different variants of edge processing and subsequent injection molding in the method according to FIG. 1,

3 shows a second embodiment of the method according to the invention, as well as

FIG. 4 shows two different variants of edge processing and subsequent injection molding in the method according to FIG. 3.

A first embodiment of the method according to the invention is shown schematically in successive steps A to H in FIG. In step A, a semifinished product 1 to be reshaped is first grasped in its edge area by means of a gripping device 2 and introduced into a heating device 3. The semifinished product 1 is a plate-shaped semifinished product with a polycarbonate matrix and unidirectional continuous fiber reinforcement, the fibers being carbon fibers and being arranged in several individual layers. In step B, the semifinished product 1 is heated in the heating device 3 to a temperature of 150 ° C. above the glass transition temperature T _g. This forms through the acting on the semi-finished product 1 Locking force and the heat dissipation of the gripping device 2 produce an edge marking la in the holding area of the gripping device 2.

After reaching the aforementioned temperature, the semifinished product 1 is immediately brought into a forming tool 4 with the aid of the gripping device 2. The forming tool 4 has two first and second contour parts 5, 6 that are movable relative to one another on a horizontal longitudinal axis and correspond to one another, the first contour part being movable and the second contour part 6 being fixed in the present case. In the second contour part 6, injection molding channels 7 are also provided, with which the formed semifinished product 1 can be injection molded onto, around and / or back molded with a thermoplastic polymer. The injection molding channels open into a feed line 8, via which the thermoplastic polymer can be fed centrally for injection molding. The first contour part 5 is provided on its outside with an edge processing device 9 which is held displaceably in the closing direction of the forming tool and which, in the embodiment shown in FIG. 1, is designed for flanging the edge area of the semi-finished product 1 to be formed.

In step D, the first contour part 5 is moved towards the second contour part 6 and thus the forming tool 4 is closed, as a result of which the semi-finished product 1 is given the shape predetermined by the shaped surfaces of the first and second contour parts 5, 6. In step E, the gripping device 2 is released from the edge region of the semifinished product 1, since this is now held between the first and second contour parts 5, 6 of the forming tool 4. The gripping device 2 is moved out at least so far that, according to step F, the edge processing device 9 can be moved in the longitudinal direction over the protruding edge areas of the semi-finished product 1 without colliding with the gripping device 2. When the edge processing device 9 is moved, the protruding edge regions of the semifinished product 1 are flanged by being bent by about 90 degrees with respect to their original orientation, a flanged edge 1b being produced.

In the process of the edge processing device 9 in step F, a cavity is also formed between the outer edges of the semi-finished product 1, the surface of the second contour part 6 and the inside of the edge processing device 9, with the aid of which in step G a liquid thermoplastic polymer is applied to the beaded edges to form a Edge injection 10 is injected. At the same time, the semi-finished product 1 is provided with back injections 11 in the middle area via the injection molding channels 7 using the same thermoplastic polymer.

Then, in step H, the temperature of the first and second contour part 5, 6 is lowered so that it is below the glass transition temperature of the polymer matrix of the semifinished product 1 and the glass transition temperature or melting temperature of the molded thermoplastic polymer, so that the semifinished product 1 and the molded areas 10, 11 freeze. The semi-finished product 1 is then removed from the mold by moving back the edge processing device 9 and opening the forming tool 4 by moving the first contour part 5 and actuating ejector pins (not shown here) that are installed in the second contour part 6.

In FIG. 2, steps E to G of the method according to FIG. 1 are shown again enlarged to the upper region of the shaping device 4. In the lower row in FIG. 2, in steps E 'to G', an alternative embodiment to the method according to FIG. 1 or the upper row in FIG. 2 with steps E to G are shown. As can be seen from the comparison, in the method according to steps E to G, the cavity for the edge injection molding 10 of the semifinished product 1 is essentially formed by a cutout in the second contour part 6. In contrast, in the alternative embodiment with steps E 'to G', this cavity is formed by a recess on the side of the edge processing device 9 'facing the first contour part 5.

FIG. 3 shows an alternative method according to the invention in steps C to F, steps A and B being identical to the method shown in FIG. 1. The main difference to the method shown in FIG. 1 is that the edge processing device 21 used in FIG. 3 is designed as a cutting device which, in step F, extends the protrusion 1c of the semi-finished product 1 over the outer surface of the first and second contour parts 5, 6 separates, whereby the edge marking 1 a generated by the gripping device 2 is removed from the semi-finished product 1. Analogously to FIG. 2, FIG. 4 shows an enlargement of a section of steps E and F of the separation process of the edge protrusion 1c shown in FIG. 3. In an alternative embodiment in steps E 'to G', after the process of separating the edge overhang 1c, the semi-finished product 1 is injected with a thermoplastic polymer on its side edge via an injection molding channel 7. For this purpose, the edge processing device 21 'designed as a cutting tool has a cavity on its side facing the first contour part 5, which is positioned so that in step F' it spans the outer edge of the semifinished product 1 and the outlet opening of the injection molding channel 7 after the edge protrusion lc has been cut off so that a thermoplastic polymer injected via the injection molding channel 7 in step G ′ forms an edge injection molding 10 on the side edge of the semifinished product 1. List of reference symbols

1 semi-finished product la edge marking lb flanged edge lc cut overhang

2 gripping device

3 heating device

4 forming tool

5 First contour part 6 Second contour part

7 injection molding channels

8 inflow line

9 Edge processing device

9 ’Edge processing device 10 Edge injection

11 back injection

21 Edge processing device

21 'edge processing device

Claims

Patent claims:

1. A method for reshaping a semi-finished product (1) made of a thermoplastic polymer fiber composite material in an injection molding machine, comprising the following steps a) heating the semi-finished product in a heating device (3) to at least the glass transition temperature Tg or the melting temperature TS of the polymer matrix of the thermoplastic polymer fiber composite material and Gripping the semifinished product with a gripping device (2) in at least one edge region of the semifinished product (1) and placing the semifinished product (1) in a forming tool (4) with at least two first and second contour parts that are movable relative to one another in a horizontal direction and that correspond to one another (5, 6) with mutually facing mold surfaces, the semifinished product (1) being introduced between the contour parts (5, 6) in such a way that the semifinished product (1) protrudes over the edge of the mold at least in the held edge area and has a protrusion forms, b) moving the contour parts (5, 6 ) and forming the semi-finished product (1), which immediately before contact with the mold surfaces at least the

Glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material, c) releasing and moving the gripping device (2) out of the area of the contour parts (5, 6), and d) method one on the outside of at least the first contour part in the closing direction of the forming tool (4) displaceably held edge processing device (9) at least over the previous holding area of the gripping device (2), wherein the protrusion is flanged and / or cut off at least in the held edge area, e) on, around and / or Injection molding of the formed semi-finished product, steps a) to e) being carried out in only this one forming tool.

2. The method according to claim 1, characterized in that in step (b) at least 90% of the maximum achievable locking force of the injection molding machine within five (5) seconds or less, preferably within three (3) seconds or less, particularly preferably within one (1) second or less, very particularly preferably in half a second or less, after the forming tool has been brought together completely on the semifinished product.

3. The method according to claim 1 or 2, characterized in that the formed semifinished product (1) still has a temperature of at least the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material when flanging or cutting off the protrusion.

4. The method according to any one of the preceding claims, characterized in that the formed semifinished product (1) has a temperature below the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material when separating the supernatant.

5. The method according to any one of the preceding claims, characterized in that the edge processing device (9) is designed as a continuous frame or is composed of several individually or jointly displaceable segments, the segments of the edge processing device (9) preferably in part for the flanging and another part are designed to cut off the supernatant.

6. The method according to any one of the preceding claims, characterized in that in step c) the gripping device (2) is moved out of the area of the contour parts (5, 6) at least so far that the edge processing device (9) is not involved in the process the gripping device (2) collides.

7. The method according to any one of the preceding claims, characterized in that in at least one of the contour parts (5, 6) at least one melt feed line (7) is formed, which opens into the mold surface of this contour part, the formed semi-finished product (1) through this melt feed line (7) on the side facing the contour part (5) during or after the reshaping with closed contour parts (5, 6) is injected with a thermoplastic polymer, the thermoplastic polymer to be injected and the semi-finished product (1) preferably at a temperature of during the injection process have at least the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material.

8. The method according to any one of the preceding claims, characterized in that when the edge processing device (9) is in the process of reaching the end position between the edge processing device (9) and the second contour part (6), a cavity is formed which is in fluid communication with a melt feed line (7) running through the second contour part (6) and injection molding of a thermoplastic polymer onto, around and / or back injection of the beaded overhang, the thermoplastic polymer to be injected being injected during the molding on, around and / or back injection process and the semi-finished product (1) preferably have a temperature of at least the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material.

9. The method according to any one of the preceding claims, characterized in that the semi-finished product (1) after the forming and optionally injection molding, molding and / or rear injection below the glass transition temperature T _g or the melting temperature Ts of Polymer matrix of the thermoplastic polymer fiber composite is cooled and then removed from the mold.

10. The method according to any one of the preceding claims, characterized in that the polymer matrix of the thermoplastic polymer fiber composite material is selected from polycarbonate (PC) or its blends, in particular with acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile copolymer (SAN), Polyethylene terephthalate (PET) and / or polybutylene terephthalate (PBT), polymethyl methacrylate (PMMA), polyphenylene sulfide (PPS), polyamide (PA), polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), polyetheretherketone (PEEK), polyaryletherketone (PAEK) ), thermoplastic polyurethane (TPU), acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile copolymer (SAN), polyethylene terephthalate (PET), polybutylene terephthalate (PBT) or mixtures of these, with polycarbonate (PC) and its blends as well as thermoplastic Polyurethane (TPU) are particularly preferred.

11. The method according to any one of the preceding claims, characterized in that the fiber reinforcement of the thermoplastic polymer fiber composite material is selected from glass, polymer, in particular aramid or Kevlar fibers, carbon fibers and natural fibers, preferably from glass and carbon fibers , wherein the fibers are preferably continuous fibers.

12. The method according to any one of the preceding claims, characterized in that the fiber reinforcement of the thermoplastic polymer fiber composite material is selected from scrim, knitted fabric, woven fabric, fleece, mat, knitted fabric, braid, unidirectional fiber layer or combinations thereof.

13. The method according to any one of the preceding claims, characterized in that the forming tool is designed so that the tool cavity of the forming tool does not have any fixing pins, folding pins, one-sided or two-sided slide elements, or clamping devices.

14. Formed folded product (1) obtainable by a method according to one of claims 1 to 13.

15. Use of a formed folded product (1) according to claim 14 in the automotive sector, in particular in visible and structural components, preferably hubcaps, center console cladding, headrests, flood shelves, door handles, pillar cladding, spoilers, door sills, mirror covers, radiator grills, front grills, fan slats, in luggage, preferably in suitcases, in furniture, preferably in chairs, tables, cupboards, especially for furniture in vehicles, preferably in mobile homes or caravans, in or on bicycles, preferably on e-bikes, racing bikes, mountain bikes, gravel bikes, city bikes , as structural components on bicycles, preferably frames, forks, forks, as attachments, preferably as saddles, Seat post, recordings, springs, cranks, and in sports equipment, preferably for hockey, tennis, football, rugby, as sticks, helmets, protective equipment, shin guards, arm guards, skis, ski boots, wakeboards, surfboards, paddles, diving fins and generally as reinforcement elements in clothing , preferably shoe soles, in electronic devices, preferably drones, monitors, tablets, mobile phones, laptops or computers, especially in a laptop, or in housing parts that are suitable for use as or in a housing of an electronic device, in medical devices , preferably orthotics, prostheses, in household appliances, as equipment for aircraft and rail vehicles.

16. Device for forming a semifinished product (1) made of a thermoplastic polymer fiber composite material comprising an optional heating device (3) for heating the semifinished product (1) to at least the glass transition temperature T _g or the melting temperature Ts of the polymer matrix of the thermoplastic polymer fiber composite material and a movable gripping device ( 2) for gripping the semifinished product (1) to be formed in at least one edge area of the semifinished product (1), the gripping device (2) moving the semifinished product (1) into a forming tool (4) with at least two relative to a substantially horizontally aligned longitudinal axis first and second contour parts (5, 6) that are movable to one another and corresponding to one another and with facing mold surfaces, and the semi-finished product (1) can be introduced between the contour parts (5, 6) with the gripping device (2) in such a way that this is at least in the held edge area beyond the edge of the form surfaces beyond gene and can form a protrusion, wherein the contour parts (5, 6) for forming the semi-finished product (1) can be moved towards each other, and wherein on the outside of at least the first contour part (5) one in the longitudinal axis of the forming tool (4) at least over the Holding area of the gripping device (2) displaceably held edge processing device (9) is provided, which is suitable for flanging or cutting off the excess, and wherein the device is designed as an injection molding machine or is part of an injection molding machine or is assigned to an injection molding machine.

17. The device according to claim 16, characterized in that the forming tool is designed so that the tool cavity of the forming tool does not have any fixing pins, retaining pins, clamping devices and / or one-sided or two-sided slide elements.