Patent Application
20170157819
The invention relates to a method for producing an injection-molded component with an inlay consisting of an organo sheet, to a device for carrying out the method and to an injection-molded component produced by the method.
Organo sheets are fiber composite materials which are currently used primarily in motor vehicle and aircraft construction. There is further potential in the manufacture of front ends, seats, carriers and pedals.
Organo sheets are semifinished fiber-matrix products. They consist of a fiber fabric or a fiber crosslay which are embedded in a thermoplastic matrix. The advantages of a thermoplastic matrix reside in the hot formability of the semifinished products and the shorter process times, resulting therefrom, compared with conventional thermosetting fiber composite materials. This is of great advantage particularly in the automotive industry with its short process times. Frequently used fiber materials are glass, aramid and carbon. In fabrics and crosslays, the fibers can also extend at right angles to one another, such that the mechanical properties of organo sheets, such as rigidity, strength and thermal expansion, can be defined better than in their metal precursors. In contrast to metal sheets, the tensile and compressive behavior and other mechanical and thermal properties are not isotropic.
Consolidated semifinished organo sheet products are known, which are first of all formed into inlay parts in a separate step, are subsequently laid in an injection mold and then overmolded.
Disadvantages of consolidated semifinished organo sheet products are in particular the high costs for the semifinished products, the poor energy balance (heating twice to three times for consolidation, forming and heating for overmolding required), the complicated handling devices in the case of a large number of or large organo sheets, the necessary trimming of the organo sheet or component trimmings and the necessary higher manufacturing tolerances in consolidated organo sheet inlay parts, in order to prevent damage to tools.
Not yet consolidated organo sheets are also known, which are available as endless products on a roll.
Therefore, it is an object of the present invention to provide a method, a device and a component which avoids, or at least reduces, the disadvantages of the prior art.
This and other objects are achieved by a method for producing an injection-molded component with an inlay made of an organo sheet. The method has the following steps of:
With the aid of the method according to the invention, the high costs for semifinished products can be reduced, since unconsolidated material is used. The energy balance is improved since heating for consolidating, forming and the injection-molding process is necessary only once. The complicated handling devices in the case of a large number of, or large, organo sheets and the necessary higher manufacturing tolerances for consolidated organo sheet inlay parts can be eliminated.
According to a preferred development, the heated portion is severed from the endless organo sheet prior to or during the introduction into an open injection mold.
According to an advantageous development, the heated portion is drawn further into the injection mold by the forming operation, such that the cut edge is no longer located in the region of the component edge of the finished injection-molded component.
According to a preferred configuration, the severed portion is formed by use of an advancing slide which moves into the injection mold for forming and leaves the injection mold again after the forming process has been completed, in order to form a cavity for the injection-molding process in the injection mold.
The object according to the invention is also achieved by a device for producing an injection-molded component with an inlay made of an organo sheet. The device includes:
According to an advantageous development, in order to form the severed portion of the endless organo sheet, an advancing slide is provided, which is extendable and retractable with respect to the injection mold.
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of one or more preferred embodiments when considered in conjunction with the accompanying drawings.
Arranged between the injection mold 4 and the roll 3 is a heating station 5.
In a first method act, by use of a gripper (not illustrated), a front portion (section) of the endless organo sheet is drawn from the roll 3 and introduced into the heating unit 5. This is shown in
In the heating unit 5, that portion of the organo sheet 2 that is located in the heating unit 5 is heated to a temperature which is above the forming temperature of the organo sheet 2.
Following completion of the heating phase, that portion of the organo sheet 2 that is located in the heating unit 5 is taken by a clamping frame 6 and transported in the direction of the injection mold 4, which is open at this time. In this case, that portion of the organo sheet 2 that is located in the heating unit 5 is still connected to the endless organo sheet located on the roll 3. As a result, during the transport of the portion located in the heating unit 5, a further portion of the endless organo sheet is automatically drawn from the roll 3 and introduced into the heating unit 5. This is shown in
When the state shown in
Subsequently, first of all that portion of the organo sheet 2 that is located in the injection-molded component 1 is formed into the inlay or consolidated, and subsequently, the inlay is overmolded to produce the injection-molded component 1.
After the injection mold 4 has been opened and the finished injection-molded component 1 has been removed, the described production process can start again from the beginning, by an already heated portion being drawn from the heating station 5 into the injection mold 4.
In order that the cutting edge of the organo sheet 2 is no longer located in the region of the component edge of the finished injection-molded component 1, the heated portion is drawn further into the injection mold 4 during the forming operation, as can be seen in
The forming of that portion of the organo sheet 2 that is located in the injection mold 4 into an inlay takes place by use of an advancing slide (not illustrated) which moves into the injection mold 4 for forming and leaves the injection mold 4 again after the forming process has been completed, in order to form a cavity for the injection-molding process in the injection mold 4.
The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2014 224 125.1 | Nov 2014 | DE | national |
This application is a continuation of PCT International Application No. PCT/EP2015/075502, filed Nov. 3, 2015, which claims priority under 35 U.S.C. §119 from German Patent Application No. 10 2014 224 125.1, filed Nov. 26, 2014, the entire disclosures of which are herein expressly incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/EP2015/075502 | Nov 2015 | US |
| Child | 15434160 | US |
