CN101180169A - 用于成型结构片材的工艺和模具 - Google Patents

用于成型结构片材的工艺和模具 Download PDF

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CN101180169A
CN101180169A CNA2006800175404A CN200680017540A CN101180169A CN 101180169 A CN101180169 A CN 101180169A CN A2006800175404 A CNA2006800175404 A CN A2006800175404A CN 200680017540 A CN200680017540 A CN 200680017540A CN 101180169 A CN101180169 A CN 101180169A
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sheet
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CN101180169B (zh
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乔治·韦内尔
阿德里亚诺·奥迪诺
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Leinuolitegeer Co. Ltd.
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Renolit SE
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
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    • B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
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    • B29C2043/026—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface having functional projections, e.g. fasteners
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/34—Feeding the material to the mould or the compression means
    • B29C2043/3444—Feeding the material to the mould or the compression means using pressurising feeding means located in the mould, e.g. plungers or pistons
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/361—Moulds for making articles of definite length, i.e. discrete articles with pressing members independently movable of the parts for opening or closing the mould, e.g. movable pistons
    • B29C2043/3613—Moulds for making articles of definite length, i.e. discrete articles with pressing members independently movable of the parts for opening or closing the mould, e.g. movable pistons applying pressure locally
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/361—Moulds for making articles of definite length, i.e. discrete articles with pressing members independently movable of the parts for opening or closing the mould, e.g. movable pistons
    • B29C2043/3615—Forming elements, e.g. mandrels or rams or stampers or pistons or plungers or punching devices
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C2043/3665—Moulds for making articles of definite length, i.e. discrete articles cores or inserts, e.g. pins, mandrels, sliders
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/58—Measuring, controlling or regulating
    • B29C2043/5875—Measuring, controlling or regulating the material feed to the moulds or mould parts, e.g. controlling feed flow, velocity, weight, doses
    • B29C2043/5883—Measuring, controlling or regulating the material feed to the moulds or mould parts, e.g. controlling feed flow, velocity, weight, doses ensuring cavity filling, e.g. providing overflow means
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/25—Solid
    • B29K2105/253—Preform
    • B29K2105/256—Sheets, plates, blanks or films
    • 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
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • 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
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3041—Trim panels

Abstract

用来成型片材的工艺，该片材局部具有三维突出或凹陷结构(6)，其中坯料片材(7)置于模具的两个部分之间，该模具的表面对应于所述三维结构的负结构(2)。依赖于三维结构是突出的还是凹陷的，围绕所述负结构的模具的表面的至少一部分具有用于形成局部贮料池的特征，所述贮料池能够提供或容纳该三维结构的材料。

Description

用于成型结构片材的工艺和模具
本发明涉及用来成型结构片材的一种工艺和一种模具。术语“结构片材”应被理解为意味着一种零件，该零件基本上具有两个维度，并且因此可由平面零件的连续变形产生，其厚度大大小于(以至少100倍)其宽度和长度，但是其包括数个具有三维结构的附加物。这可以是例如与该片材成型为一个零件的紧固肋条或系统。机动车辆的内衬常常包括由热塑性材料制成的这种结构片材。
一种已知的生产这种结构片材的手段是熔融材料在模具中的成型。塑料的任何注射成型和铝的铸造的例子是熟知的。在塑料注射成型工艺中，塑料在进料螺杆中被加热并混合，并且贮存在贮料器中。当贮料器充满时，其容纳物被注射到温度受调节的闭合的模具中，在该模具中，材料被冷却。当材料达到足够低的温度以具有适当的机械强度时，打开模具并且弹出零件。然而，特别地，当结构片材是薄的时候，熔融材料的注入需要高的压力，并且因此需要重的且昂贵的机械。
同样公知的是，将压力成型与注射成型组合，例如在EP 1 153 725中描述的情况。在这种工艺中，二维零件通过压力成型而成型，而三维零件被注射成型。然而，能够承受高压的注射成型机械和模具仍是必需的，由此增加了该工艺的成本。
本发明的目的在于提供一种简化的工艺，用于生产低成本的结构片材。
因此，本发明涉及一种用来成型片材的工艺，该片材局部地具有三维突出或凹陷结构，其中坯料片材置于模具的两个部分之间，其表面与所述三维结构的负结构(negative)一致，并且模具闭合以便压缩坯料片材并迫使它流入到三维结构中。根据本发明，依赖于三维结构是突出的还是凹陷的，围绕所述负结构的模具的表面的至少一部分分别具有突出或凹陷特征，该突出或凹陷特征分别用于排出或容纳该三维结构的材料。
措辞“突出的三维结构”应被理解为意味着由与片材相同的材料制成的任何附加物或附属物，希望的是，该附加物或附属物与该片材成一体。典型地，这些是加强肋条，或者例如紧固系统。它们还可以是超厚的，用于减少成型压力。凹陷结构是在成型期间在片材中制出的凹陷，允许随后将任何有用的附属物引入到它中。
已经观察到，构成小“贮料池”的这种特征的存在限制了在成型期间材料必须流过的路径的长度，并且因此减少成型压力。这导致了较低的锁模力，并且因此导致了较轻的且不太昂贵的机械。而且，当三维结构是突出的时候，获得了负结构的较好的填充。当该结构是凹陷的时候，避免了不受控的超厚度或表面缺陷(缩痕)。
在根据本发明的工艺的第一优选方案中，三维结构是突出的并且模具的特征是凸起，该凸起用于在模具闭合时局部地减少在模具的两个部分之间提供的空间，以便迫使材料渗入负结构中并且形成该三维结构。因此结构片材将在该结构周围略薄。凸起的厚度和面积依赖于三维结构的体积，它们的乘积必须接近该体积并且在可能的情况下略微大于该体积(因此，该贮料池的体积对应于形成该结构所需的材料的体积)。有利地，该厚度比片材的厚度大1％，优选地5％，更优选地10％。所推荐的是，该减少量保持小于片材厚度的50％，优选地30％，更优选地20％。对于厚度为2mm的片材，凸起的厚度将理想地是在0.2和0.4mm之间，局部地给出了1.6和1.8mm之间的片材厚度。根据本发明的工艺适用于成型厚度广泛变化(例如在0.5和10mm之间)的片材。然而，该工艺特别有利于成型具有小于5mm、优选地小于4mm的厚度的薄的片材。它特别适用于具有2和3mm之间的总厚度的片材。该负结构以已知的方式配备有通气系统。
在根据本发明的工艺的第二优选方案中，该三维结构是突出的，并且模具的表面具有在模具闭合时可缩回的凸起，该凸起局部地增加坯料片材的面积，从而提供用于产生突出结构的材料。该可缩回的凸起可以例如安装在弹簧上。当模具打开时，凸起使负结构附近的坯料片材升起。这导致了对应于升起的区域的侧面的坯料片材的超额的面积。当模具闭合时，弹簧被压缩并且凸起缩回到模具中。超额的量的坯料片材用于填充负结构，而不需要材料流过长的距离，可缩回的凸起被安置在负结构附近。凸起的高度被确定为近似地且略微超额地提供形成三维结构所需的材料的量。
根据本发明的工艺可以应用于具有足够的流动性的任何材料，以通过在压力下流动而允许三维结构的成型和形成。如果需要，通过加热材料可以获得该流动性。
在实施该工艺的一个有利方法中，坯料片材由流体塑料(fluidplastic)制成。当塑料包括纤维时，根据本发明的工艺是特别有利的，这是因为，在该情况中，在已知的工艺中，材料难于流动到三维结构上。这些可以是玻璃纤维或者任何无机材料的纤维，也可以是有机纤维，诸如棉或木质纤维。该塑料可以是热固性塑料或热塑性塑料。优选地，它是热塑性塑料，例如，诸如聚丙烯的聚烯烃。材料的精确选择将依赖于适当地形成三维结构所需的流动性，并且例如，还依赖于片材的最终覆层，以便于适当地与其粘结。在这种情况中，通过将材料加热到高于其软化温度可以容易地获得所需的流动性。在这种实施方法中，将模具冷却到低于该软化温度的温度，以便使具有良好的机械属性的零件脱模。所推荐的是，在模具闭合之前，使用用来防止坯料片材的不均匀的和过早的冷却的任何手段，例如，借助于辐射或热空气循环。
根据本发明的工艺可用于成型在其两面上均具有三维结构的结构片材。然而，在一个特别有利的方案中，片材仅在其一个面上具有三维结构。在这个方案中，当坯料片材由流体塑料制成时，有利的是，预期保持平滑的面由纤维层覆盖，以便提高其机械完整性，并且因此使其更易于处理并减少塑料粘附到设备的风险。而且，在这个方案中，根据本发明的工艺可以获得没有表面缺陷的平滑的面。当三维结构是深的时候，这是特别有利的，这是因为，在该情况中，已知的工艺不允许获得没有缩痕的平滑的片材“背面”。当材料是晶体聚合物时，根据本发明的工艺的这个优点更加显著，晶体聚合物在结晶时的收缩以已知的方式在大的肋条或超厚度的反面上引起缩痕。在这个方案中，不具有三维结构的面的优良的表面光洁度允许它覆有符合片材的表面光洁度的薄的柔性层，该覆层例如用于装饰性目的。该覆层可以是例如织物、塑料的片材，诸如柔性PVC、或者皮革。该覆层可以有利地在片材的成型期间生产。
因此，在实施这个方案的一个方法中，在模具闭合之前，使柔性覆层叠加在预期保持平滑的坯料片材的那个面上。
在这个实施方法中，有利的是，将纤维层放置在坯料片材和覆层之间，以便避免在成型期间覆层的表面光洁度的任何变形。所推荐的是，该纤维层是由棉纤维或玻璃纤维形成的纤维织物。
在根据本发明的工艺中，使用具有特定的内部表面特征的、在三维结构的负结构周围提供材料贮料池功能的模具。
因此，本发明还涉及一种用于成型片材的模具，它局部地具有三维突出或凹陷结构，所述模具包括所述三维结构的负结构，围绕所述负结构的该模具的表面的至少一部分具有用于形成局部贮料池的特征，该贮料池能够依赖于三维结构是突出的还是凹陷的，分别提供或容纳该三维结构的材料。
根据本发明的模具的推荐方案，三维结构是突出的并且模具的特征是凸起，该凸起用于在模具闭合时局部地减少留在模具的两个部分之间的空间，以便迫使材料渗入负结构中并且形成三维结构。
同样有利的是，在根据本发明的模具中，三维结构是突出的并且模具的表面具有在模具闭合时可缩回的凸起，该凸起局部地增加了坯料片材的面积，由此提供了用于产生突出结构的材料。
通过附图的以下描述，本发明的特定的方面将显现。
图1到4是示出了根据本发明的工艺和模具的多个方面的简图。
图5在5a示出了已知的成型工艺，并且在5b示出了根据本发明的工艺和模具的优选方案。
图1示出了根据本发明的模具的负结构(2)和工艺，以及优选方案的凸起(1)。
在图2到4中，可以看到放置在由填充木质纤维的聚丙烯制成的坯料片材和柔性PVC覆层(4)之间的玻璃纤维织物，不包含三维结构的平滑面(5)和位于另一面上的三维结构(6)。
图5示出了覆层(4)、坯料片材(7)、可缩回的凸起(10)和三维结构的负结构(2)。图5b示出了由弹簧(8)致动的可缩回的凸起引起在坯料片材(7)上出现侧面(9)，由此构成用于填充负结构(2)的材料供应。
下面的例子用于说明本发明
例子
填充有30％的木质纤维、覆盖有厚度为1.5mm且相对密度为1.06的聚丙烯和洋麻纤维的织物的聚丙烯的片材(尺寸为2.5×250×250mm的BP、HCW、MFI 20)被放置在图1中示出的模具上。在负结构(2)周围，模具具有厚度为0.5mm的凸起(1)。密度为1200g/m2的由柔性PVC组成的覆层被布置在玻璃纤维织物的顶部上。将坯料片材预热到210℃的温度。借助于调节流体的循环将模具保持在50℃的温度。然后闭合模具，施加60吨的力持续30秒的时间。在模具打开后，获得了图4中示出的具有三维结构(6)的片材。

Claims (12)

1.用来成型片材的工艺，所述片材局部地具有三维突出或凹陷结构(6)，其中坯料片材(7)放置于模具的两个部分之间，所述模具的表面对应于所述三维结构的负结构(2)，并且所述模具闭合以便压缩所述坯料片材(7)并迫使其流入所述三维结构，其特征在于，依赖于所述三维结构是突出的还是凹陷的，围绕所述负结构的所述模具的所述表面的至少一部分分别具有突出或凹陷特征，所述突出或凹陷特征分别用于排出或容纳所述三维结构的材料。
2.如前一项权利要求所述的工艺，其中所述三维结构是突出的并且所述模具的所述特征是凸起(1)，所述凸起用于在所述模具闭合时局部地减少在所述模具的所述两个部分之间提供的空间，以便迫使所述材料渗入所述负结构(2)中并且形成所述三维结构(6)。
3.如前面权利要求的任一项所述的工艺，其中所述三维结构是突出的并且所述模具的所述表面具有在所述模具闭合时可以缩回的凸起(10)，所述凸起通过侧面(9)的出现局部地增加所述坯料片材的面积，由此提供用于产生所述突出结构的材料。
4.如前面权利要求的任一项所述的工艺，其中所述坯料片材由流体塑料制成。
5.如前一项权利要求所述的工艺，其中所述流体塑料是已被预热到高于其软化点的热塑性塑料，并且其中所述模具被调节在低于所述软化点的温度。
6.如前面权利要求的任一项所述的工艺，其中所述片材仅在其一个面上具有三维结构。
7.如前一项权利要求所述的工艺，其中，在所述模具闭合之前，柔性覆层被叠加在预期保持平滑的所述坯料片材的那个面上。
8.如前一项权利要求所述的工艺，其中纤维层被放置在所述片材和所述覆层之间
9.如前一项权利要求所述的工艺，其中所述纤维层是纤维织物。
10.用于成型局部地具有三维突出或凹陷结构的片材的模具，其包括所述三维结构的负结构，围绕所述负结构的所述模具的所述表面的至少一部分具有用于形成局部贮料池的特征，所述贮料池能够依赖于所述三维结构是突出的还是凹陷的，分别提供或容纳所述三维结构的材料。
11.如前一项权利要求所述的模具，其中所述三维结构是突出的并且所述模具的所述特征是凸起，所述凸起用于在所述模具闭合时局部地减少留在所述模具的所述两个部分之间的空间，以便迫使所述材料渗入所述负结构中并且形成所述三维结构。
12.如权利要求10和11中的任一权利要求所述的模具，其中所述三维结构是突出的并且所述模具的所述表面具有在所述模具闭合时可缩回的凸起，所述凸起局部地增加所述坯料片材的面积，由此提供用于产生所述突出结构的材料。
CN2006800175404A 2005-05-20 2006-05-18 用于成型结构片材的工艺和模具 Expired - Fee Related CN101180169B (zh)

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