EP2655035A1 - Process for producing surface-finished lightweight components with high natural fibre content and integrated fastening elements - Google Patents
Process for producing surface-finished lightweight components with high natural fibre content and integrated fastening elementsInfo
- Publication number
- EP2655035A1 EP2655035A1 EP11805495.6A EP11805495A EP2655035A1 EP 2655035 A1 EP2655035 A1 EP 2655035A1 EP 11805495 A EP11805495 A EP 11805495A EP 2655035 A1 EP2655035 A1 EP 2655035A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- component
- semi
- natural fiber
- finished product
- finished
- Prior art date
- Legal status (The legal status 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 status listed.)
- Withdrawn
Links
Classifications
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- 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
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1671—Making multilayered or multicoloured articles with an insert
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- 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
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
- B29C2045/14286—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure means for heating the insert
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- 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
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
-
- 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
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2311/00—Use of natural products or their composites, not provided for in groups B29K2201/00 - B29K2309/00, as reinforcement
- B29K2311/10—Natural fibres, e.g. wool or cotton
Definitions
- a process for the production of lightweight components is presented, which have a high natural fiber content and a finished surface. Furthermore, an apparatus for carrying out said method will be described. Such components are preferably used in the automotive industry.
- Natural fiber-reinforced plastic components also referred to below as NFK components, of the automotive interior are mostly produced on the basis of flat semi-finished products, predominantly by pressing.
- natural fiber content of over 80 wt .-%, a low material density and high structural characteristics can be achieved.
- the design freedom of the press components with regard to local structural stiffening, z. B. by reinforcing ribs, as well as implementation of fasteners, such as retainers very limited.
- the implementation of soft surfaces requires subsequent component lamination.
- the injection molding technology allows a virtually unlimited molding geometry and a surface lamination in a single-stage process, however, has in the processing of natural fiber reinforced plastics significant restrictions on recoverable natural fiber content, highly dynamic structural properties and temperature-related odor emissions. Furthermore, the material density is significantly higher than that of the NFK press components.
- DE 103 27 725 A1 describes a method in which a composite component is produced by applying to the component side of a decorative layer a flowable plastic compound which is loaded with an expandable gas.
- the plastic mass is introduced into a mold space and the gas begins, initiated by a pressure reduction, to expand and to expand the originally single-phase plastic mass into a porous plastic foam, which completely fills the mold space.
- DE 103 41 855 A1 discloses a method of producing a component which may comprise fibers, in particular natural fibers, with a proportion of up to 70% by weight.
- the component consists of a plastic foam, which is covered with a decorative film.
- the preparation takes place by using a gas-permeable decorative layer and the plastic in the mold, is foamed behind the decorative film. Excess gas can advantageously pass through the decorative film and leave the process room.
- the foaming of the plastic is preferably carried out by chemical foaming based on a gas-forming reaction.
- a decorative or trim part for a vehicle interior has a ductile insert.
- the ductile deposits are introduced into a mold and filled the space between the decorative layer and ductile layer with a plastic.
- the ductile layer should preferably consist of textile or prepreg material.
- DE 10 2004 054 228 A1 discloses a method and an apparatus for producing a composite component, wherein a molded part is produced from a natural fiber-containing blank by compression of the blank and wherein functional parts are molded by molding a plastic melt on one side of the molded part to the molded part.
- the functional parts serve to fasten a loudspeaker on one side of the molded part.
- the invention utilizes the advantages of the press, injection molding and coating technology by a combination of processes.
- the individual procedures are in one process merged. It is to be regarded as particularly advantageous that it is possible to work both with standard semi-finished products (natural fiber semi-finished products) and with standard systems, for example with an injection molding machine with dipping edge tool, with a turning plate, with a sliding table or with a turntable.
- the method provides for the following steps: a) inserting a natural fiber semi-finished product (semifinished product) into an injection mold;
- step b) After process step b), so to speak, there is a molded part with two sides. One side forms the attachment side, while the other side forms the visible side.
- the step c) relates to the attachment side whereas the step d) relates to the visible side of the molding.
- the surface component is thus applied to the side facing away from the functional elements of the molding. As a result, there is thus a lightweight finished component finished on the surface, which has functional elements on one side and a finished surface on the other side. Post-processing or subsequent surface treatment is no longer required.
- a textile material with a natural fiber content which is usually mat-like, is preferably between 30% by weight and 100% by weight, particularly preferably between 40% by weight and 90% by weight.
- the remaining percentage is formed by fillers, such as. Granules or synthetic fibers and melt fibers.
- fillers such as. Granules or synthetic fibers and melt fibers.
- thermoplastic matrix melt fibers
- the method is preferably carried out in an injection molding machine, particularly preferably in a insert injection molding machine.
- injection molding machines with a sliding table or turntable can also be used.
- a pretreated natural fiber semi-finished also called component 1
- component 1 inserted into a tool (injection mold) and pressed by the closing force to a molding and / or reshaped and consolidated.
- the molded part thus formed forms a pressed component carrier with a high degree of lightweight construction.
- partially functional elements in particular fasteners, such as retainers, and / or reinforcing structures, such.
- B. ribs, molded also called component 2).
- the injection molding takes place parallel to the pressing or is already started after a certain press-holding time in the tool. Pressing to a molding and injection molding then take place parallel or partially parallel.
- a surface component is applied on the visible side of the composite component (also called component 3), which receive on the visible side by an appropriate preparation of the forming tool surface any predetermined structuring (for example, leather look) and the component surface the desired haptic (for example, a soft -Touch effect) and / or can impart a high scratch resistance.
- any predetermined structuring for example, leather look
- the component surface the desired haptic for example, a soft -Touch effect
- the composite component can thus be supplied to another use without further processing step.
- the composite component can be attached directly to a component provided for this purpose.
- the Natural semi-finished fiber preferably has a defined melt fiber content. This melt fiber content is preferably in the range of 10 wt% to 70 wt%, and more preferably in the range of 30 wt% to 50 wt%.
- the melt fibers preferably have polypropylene as the melt component.
- the semi-finished product is tempered prior to insertion into the tool. For this purpose, a contact heater or a radiant heater device is preferably used.
- the temperature used here and the heating time depend on the composition of the natural fiber semi-finished product and, in particular, on the type and proportion of the melt component.
- the aim of tempering is to convert the melt component from the solid to the liquid or semi-liquid state. This melt component is distributed evenly under pressure in the composite structure and encloses and bonds the reinforcing fibers. Upon consolidation by cooling, this melt component becomes the matrix of the composite.
- the natural fiber semi-finished product is assembled (separated) to the required extent prior to insertion. This separation is preferably carried out by punching or trimming.
- the tool is combined with a punching device, so that the blank of the natural fiber semi-finished product is integrated into the pressing process.
- thermoset-bonded natural fiber semi-finished products are used.
- the natural semi-finished fiber products are sprayed with a reaction resin (matrix resin) (preferably polyurethane) or impregnated with a curable matrix resin (polyacrylate resin) in a dipping bath (eg in the padding process) before being placed in the mold.
- a reaction resin matrix resin
- polyacrylate resin polyacrylate resin
- the natural fiber semi-finished product is shaped and pressed.
- the process can be accelerated by the tool preferably has additional tempering.
- These tempering elements are designed for processing heat-releasing matrix materials as heating elements.
- an embodiment of the tempering elements is to be provided, which effects cooling. In this way, the necessary pressing time and thus the cycle time is advantageously shortened.
- the functional elements in particular fastening elements (retainer) and / or reinforcing structures, are injection-molded by injecting or expanding the material of these functional elements into free spaces in the tool.
- the free spaces in the tool are filled up.
- the natural semi-finished fiber is thus not back-injected over the entire surface, whereby the required closing force is advantageously significantly reduced.
- the free spaces in the tool are already present in a preferred embodiment when forming and pressing the natural fiber semi-finished product.
- the region of the semifinished product to which attachment elements and / or reinforcement structures are to be fastened is advantageously not exposed to a pressing force, so that the surface of the natural fiber semifinished product remains open-pored and advantageously rough.
- the natural semi-finished fiber is cooled less in these areas or stays warm longer. This advantageously ensures a firm connection of the material of the retainers and / or reinforcing structures with the natural fiber semi-finished product. Due to the injection / holding pressure, the natural fiber semi-finished product is also compressed at these points. An optimal connection and low component distortion are achieved by injecting the plastic during the consolidation of natural semi-finished fiber. In principle, the free spaces in the mold during molding and compression can also initially be kept closed and only released for injection molding, for example by using suitable slides. Although this eliminates the above-mentioned advantages such as porosity, on the other hand, this results in a more uniform compression and consolidation.
- the free spaces in the tool are created by processing corresponding tool parts (eg a tool half or a slide).
- a particularly close connection of the retainers, and / or reinforcing structures with the natural semi-finished fiber is achieved here, if the material of the retainer, and / or reinforcing structures with the material of the melt fiber content in the natural semi-finished fiber is identical or can form a very close connection with this.
- thermoplastic an elastomer, a thermoplastic elastomer (TPE) or even a duroplastic may be used as the material for retainers and / or reinforcing structures.
- TPE thermoplastic elastomer
- duroplastic a duroplastic
- the time of injection molding of the component 2 after closing force build-up is variable and is advantageously determined depending on the state of the component 1.
- the criterion here is the already achieved degree of hardening or consolidation of the natural fiber semi-finished product.
- the space required for the application of the surface component (component 3) in the mold cavity is preferably created by driving on a dipping edge tool or by a replaceable mold half or a replaceable tool insert.
- This free space is so large that the coating in the intended area of the visible side of the component can arise in the required strength. This is thus dependent on the thickness of the intended material layer and is preferably for a thin lacquer layer between. 0.1 mm and 1 mm, more preferably 0.4, mm to 0.6 mm. For thicker layers are preferably 1 mm to 20 mm, more preferably about 2-10 mm provided.
- a dipping edge tool is usually a tool in which the size of the cavity can be changed by moving the mold halves relative to each other.
- a dipping edge tool can be a tool with a so-called dipping edge, via which the punch and die move into one another and the mold is already circumferentially closed, wherein the depth adjustment of the cavity is still possible.
- the free space for the component 3, ie for the surface component is created by opening the tool and transferring the component into another cavity or by bringing the mold half equipped with the component together with another mold half.
- the so-called insert technology or the so-called sliding table technology or the so-called turntable technology are used. Injection molding machines with insert technology, with sliding table technology and turntable technology are familiar to the expert and therefore need not be described in detail at this point.
- component 3 is preferably a flowable composition is used, which is dimensionally stable either when cooling or by the crosslinking of reactive components.
- Component 3 is preferably a polyurethane layer with soft-touch effect or a PU lacquer layer.
- the flowable mass can also be relatively thin, for example an aqueous reactive lacquer system.
- TPE thermoplastic elastomer
- the reaction time of the surface component depends on the material used for the surface component and is preferably between about 40 and 180 s for PU systems.
- the surface component is applied in a predetermined region of the visible side of the molding.
- This predetermined area may be the entire visual page or just one or more parts thereof.
- the cutting of the component takes place only after the application of the surface component, ie after the coating with, for example, TPE / PU and thus outside of the injection mold that is used for this purpose.
- a decorative film is incorporated into the surface of the natural fiber semi-finished product, which faces the visible surface of the component, and connected to the mat in the pressing process.
- step d. of the method according to claim 1 advantageously flooded with a polyurethane lacquer system.
- the component provided with the decorative film and thus virtually "foil-laminated" component is thus additionally flooded with transparent lacquer, in this way a corresponding appearance on the finished composite component can be achieved
- a decal or laminating film printed in root wood optics could be coated with a scratch-resistant lacquer ,
- a further preferred embodiment provides for using more than three components and, for example, for printing or contouring the surface component after curing. Preference is given to a plurality of superimposed layers of surface components in the procedure of step d. educated.
- the apparatus for carrying out the method has a first mold half and a second mold half, which form a closed cavity and predetermine the shape of the desired lightweight component.
- the first tool half has free spaces which are suitable for receiving the material of the fastening elements and / or reinforcing structures.
- the free spaces may be connected to one or more material reservoirs for the material of the fasteners and / or reinforcing structures, which material may be injected under pressure.
- one or both of the mold halves can be tempered.
- an integrated in the tool halves electrical resistance heater is preferably used.
- a part of the first mold half is movable, so that the free spaces are formed only during or after the pressing process.
- the second mold half is in the case of a dipping edge tool in its entirety relative to the first mold half and the inserted semi-finished movable or, in the case of indexable insert, sliding table or turntable tool interchangeable, so that a free space is created, the entire visible side of the molding so far releases, so that the necessary amount of surface component can be introduced into this space.
- a insert injection molding machine is used, the tool has gripping elements for holding the natural fiber semi-finished mat.
- the method is thus preferably carried out on so-called horizontal injection molding machines, ie the semi-finished product is inserted in a substantially vertical position between the open mold halves of an injection mold.
- injection molding machine molding processes can be performed simultaneously on both sides of the insert.
- the two tool halves can be pressed together with pressure, wherein the pressure is generated by a unit according to the prior art.
- hydraulic drives of the injection molding machine are used for this purpose.
- FIG. 2 embodiment of the method using a reversing plate
- FIG. 1 shows the general process scheme as stated in claim 1.
- Step 1 shows the provision of the semifinished product (1) between the first mold half (4) to the left of the semifinished product and the second mold half (5) to the right of the semifinished product.
- step 2 the compression of the natural fiber semi-finished product (1) takes place in the injection mold (consisting of first and second tool half), wherein the two mold halves and the two tool halves are moved relative to each other.
- step 3 comprises the injection molding of the natural fiber semifinished material at the locations where functional elements such as in particular retainers and / or reinforcing structures are provided.
- the plastic material (2) for the functional elements, in particular for retainers and / or reinforcing structures fills the cavities of the first mold half.
- the natural fiber semi-finished product (1) was not subjected to a compressive pressure and thus is not fully consolidated there, can be achieved during injection molding a very good connection by material adhesion; the molded plastic material (2) can penetrate into the semi-finished fiber in these areas.
- the second mold half (5) is slightly withdrawn - as in the case of a dipping edge tool - or replaced with another mold half with a matched cavity to provide clearance in the given areas for the surface component (3). Subsequently, the surface component (3) is entered into this space.
- a preheated to about 200-230 ° C natural fiber semi-finished mat (for example, flax / polypropylene 50/50) is removed from the handling (11) from the heating station (12) (here a hot press) and hooked into the tool (14). Thereafter, the pressing of the semifinished product by closing the tool (14) with the associated tool on the insert (16). After a defined delay time of, for example, 10 seconds, the reshaped natural fiber semi-finished mat is partially back-injected via the injection unit (15) with plastic compound (for example polypropylene).
- the injection molding is preferably carried out in such a way that the plastic compound is injected through the semifinished product or via a melt channel deflection into a insert-side cavity in the tool on the insert (16).
- the case-molded functional elements such as retainers and / or reinforcing structures are thus located in one between the semifinished product and the Tool of the insert (16) formed cavity.
- the visible side of the molding is remote from the insert (16).
- a next semi-finished product from the semifinished product stack (13) is inserted into the heating station (12) by the handling unit (11).
- the tool (14) is opened and the insert (16) the back-injected pressed component rotated by 180 °.
- the release agent is introduced into the mold half (17) by handling (19) and at the same time taken from the handling (11) the tempered semi-finished mat from the heating station (12) and hooked into the mold half (14).
- the flooding of the pressing member with a polyurethane system which forms the surface component (3) (here PU system: Elalstolit R 8919/100 / WE35 with Iso 134/7) by means of Mixing head (18) and at the same time the pressing and injection molding of the semi-finished mat in the tool housing (14).
- a next semi-finished product is inserted into the heating station (12).
- the tool After expiry of the reaction time of the polyurethane system used of, for example, 45 seconds, the tool is opened and the finished component removed from the handling (19). Subsequently, the insert (16) is again rotated by 180 ° and registered in the mold half (17) the release agent. This process is repeated as often as desired.
- the visible side of the molding is on the side of the insert tool and the plastic composition for the functional elements is molded on that side of the semifinished product, which faces the tool (14) or the injection unit (15).
- the insert (16) is then in the inserts themselves a cavity for the polyurethane system to create, for example by suitable slide or the like.
- the polyurethane system is thus not supplied via the tool (17), but via the mold half located on the insert (16) .This can be suitably provided by docking and lifting the mixing head (18) on this mold half.
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102010063751A DE102010063751A1 (en) | 2010-12-21 | 2010-12-21 | Process for the production of surface-processed lightweight components with high natural fiber content and integrated fasteners |
PCT/EP2011/073568 WO2012085070A1 (en) | 2010-12-21 | 2011-12-21 | Process for producing surface-finished lightweight components with high natural fibre content and integrated fastening elements |
Publications (1)
Publication Number | Publication Date |
---|---|
EP2655035A1 true EP2655035A1 (en) | 2013-10-30 |
Family
ID=45463579
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP11805495.6A Withdrawn EP2655035A1 (en) | 2010-12-21 | 2011-12-21 | Process for producing surface-finished lightweight components with high natural fibre content and integrated fastening elements |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP2655035A1 (en) |
CN (1) | CN103260843A (en) |
DE (1) | DE102010063751A1 (en) |
WO (1) | WO2012085070A1 (en) |
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- 2010-12-21 DE DE102010063751A patent/DE102010063751A1/en not_active Withdrawn
-
2011
- 2011-12-21 CN CN201180058357XA patent/CN103260843A/en active Pending
- 2011-12-21 EP EP11805495.6A patent/EP2655035A1/en not_active Withdrawn
- 2011-12-21 WO PCT/EP2011/073568 patent/WO2012085070A1/en active Application Filing
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WO2012085070A1 (en) | 2012-06-28 |
DE102010063751A1 (en) | 2012-06-21 |
CN103260843A (en) | 2013-08-21 |
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