The invention relates to a method for producing an injection molding, in which a locally limited section of the injection molding is foamed selectively. The invention furthermore relates to a device for producing an injection molding of this kind
In an injection molding process, a free-flowing compound is injected into an injection mold serving as a casting mold. An injection mold of this kind typically comprises a plurality of shell parts which surround an inner mold hollow (cavity). The filling compound injected into the cavity, typically via an injection channel, is removed from the injection mold after the solidification of the material by means of an opening stroke of a shell part of the device. In the conventional injection molding method, the volume of the cavity provided by the mold is held constant up to the time of component removal, although foaming of the filling material can be achieved even in this conventional method by adding a blowing agent. For foaming wide-area structures, e.g. motor vehicle dashboards or motor vehicle door modules, a “core-back method” can then be used, in which the filling material, after complete or partial filling of the cavity, the spatial volume of the cavity is enlarged by means of an expansion stroke of one part of the mold in order to bring about foaming of the filling compound. The expansion stroke is brought about by a defined opening stroke, during which the respective mold half is opened by a defined distance, which does not yet expose the cavity.
After the solidification of the filling compound, the corresponding part of the mold is opened completely and the component is removed. With the aid of this core-back method, it is possible to produce components with very high degrees of foaming and with substantially defined edge zone thickness, making it possible to achieve an advantageous reduction in the weight of the component and the use of material.
However, the utility of the core-back method comes up against its limits as soon as the component has a geometrically challenging external geometry (e.g. a gearwheel) or contains a plurality of openings (e.g. engine cooling shroud). In this method, each component edge geometry or component opening perpendicular to the opening stroke gives rise to a high outlay in the production of the mold since the edge geometries in the core-back method each have to be reproduced in both mold halves and the mold halves must provide an accurately toleranced seal with respect to one another for the entire expansion stroke in order to prevent overpacking
This method is therefore used essentially only for geometrically simple components of wide-area design, preferably having few openings or none, such as dashboards or door modules. Moreover, the expansion stroke technique in the conventional core-back method does not allow the production of components with component areas that are locally thin-walled transversely to the direction of the stroke of the mold halves and which are smaller than the distance which the mold travels during the expansion stroke. It is therefore not feasible, for example, to produce engine cooling fans which have thin-walled component areas for aerodynamic reasons (efficiency) using the conventional core-back method.
It is therefore the object of the invention to simplify the production of foamed components with complex component boundary geometries or thin-walled component regions.
According to the invention, a method for producing an injection molding with the aid of an injection molding device, wherein a filling compound is injected into a cavity of the injection molding device and is foamed with the aid of an expansion stroke. In this process, a displacer element limited to a selected section of the cavity is introduced into the cavity, and the filling compound is injected into the cavity with the displacer element arranged therein. In a subsequent expansion stroke, the displacer element is moved out from the cavity in order to foam the filling compound in the selected section of the cavity. With the aid of the expansion stroke locally limited to a particular section of the cavity, it is possible to foam even components with complex shapes. In particular, it is also possible to foam components with thin-walled sections, even without the expenditure on tooling which is normally necessary for this purpose.
In an advantageous embodiment, provision is made for the expansion stroke of the displacer element in the selected section of the cavity to produce a higher degree of foaming of the filling compound than in an adjacent section of the cavity. The different degrees of foaming allow a greater flexibility in the design of the components. Moreover, it is possible selectively to save weight and component material by means of selected sections with higher degrees of foaming.
Another advantageous embodiment envisages that the expansion stroke of the displacer element produces foaming of the filling compound which is limited substantially to the selected section of the cavity. This allows even greater flexibility in the design of the components.
In another advantageous embodiment, it is envisaged that filling compound continues to be injected into the adjacent section of the cavity during the expansion stroke of the displacer element in order to produce a low degree of foaming in this section. It is thereby possible selectively to keep the density high in particular component sections in order to make said component sections capable of bearing higher mechanical loads, for example.
In another advantageous embodiment, provision is made for the expansion stroke of the displacer element to produce a substantially uniform degree of foaming of the filling compound in the entire cavity. This allows foaming of regions or sections of the cavity which can be foamed only with a large amount of technical effort, if at all, by conventional methods, owing to the geometry of said cavity.
Another advantageous embodiment envisages that the expansion stroke of the displacer element is limited to the thick-walled section of the cavity, whereas no expansion stroke takes place in an adjacent, thin-walled section of the cavity. It is advantageous to limit the expansion stroke to a thick-walled section of the cavity, in particular if thin-walled regions, the thickness of which is less than the expansion stroke, are being produced.
In another advantageous embodiment, provision is made for a first displacer element, which is limited to a first selected section of the cavity, and a second displacer element, which is limited to a second selected section of the cavity, to be introduced into the cavity, wherein the filling compound is injected into the cavity with the displacer elements arranged therein. In this case, the displacer elements are moved out from the cavity simultaneously or in succession during the subsequent expansion stroke in order to foam the filling compound in the selected sections of the cavity. By using a plurality of displacer elements, it is also easy to produce relatively complex components. Here, the displacer elements do not have to have the same stroke direction. If, as is the case in a further embodiment, the displacer elements are moved out from the cavity in succession during the subsequent expansion stroke in such a way that the filling compound in the selected sections of the cavity is foamed to different degrees, this opens up the possibility of producing even very complicated components.
According to the invention, a device for producing an injection molding is furthermore provided, comprising a cavity formed from shell parts. In this case, at least one displacer element is provided, which is designed in such a way that it can be plunged into the cavity in a region limited to a selected section of the cavity. A mold of this kind is significantly easier to produce than a conventional mold for the production of components of complex construction.
In an advantageous embodiment, it is envisaged that the displacer element is arranged so as to be movable between at least one extended position, in which at least one part of the displacer element plunges into the cavity, and an end position in which one surface of the displacer element forms a boundary of the cavity. The use of a plurality of extended positions makes it possible to vary the degree of foaming.
In another advantageous embodiment, it is envisaged that the displacer element is designed as a piston that can be plunged into the cavity. Such components of the mold are particularly easy to produce.
In another advantageous embodiment, it is envisaged that the displacer element is integrated into one of the shell parts. This enables the mold to be used easily. By actuating the displacer element integrated into a shell part, it is furthermore easier to remove the finished component from the corresponding shell part after the opening of the mold.
Another advantageous embodiment envisages that the movable element is arranged between two shell parts. This embodiment enables the mold to be produced more easily.
In another modification, it is envisaged that a locking mechanism is provided for fixing the movable element in the first position thereof. This makes it possible to dispense with a drive for the expansion stroke. This, in turn, allows a simple mold construction.
Finally, another modification envisages that the locking mechanism is designed as a locking bar element that can be moved orthogonally to the expansion stroke. A locking bar element of this kind represents a particularly simple locking mechanism.
The invention is described in greater detail below with reference to drawings, in which:
In a subsequent method step, a free-flowing compound, generally a suitable plastic, is injected into the cavity 200 of reduced volume. The fluid plastic compound 301 is typically fed in via at least one feed channel. The feed channel, which is not shown here, can open into one of the edge sections 210, 230 of the cavity 200, for example. The filling compound 301 can fill the cavity 200 of reduced volume completely, as is the case here, or only partially.
In the following method step, the preform formed by the injected filling compound 301 is foamed by means of an expansion stroke 132 of the slide mechanism 130. For this purpose, the slide mechanism 130 can be pulled out of the cavity 200 up to an end position, as illustrated in
As shown in
However, it is also possible, by means of the method according to the invention, to produce components with non-homogeneous foaming. By controlling the pressure, temperature and/or the speed of the expansion stroke, the morphology of the foam structure formed can be selectively influenced. In certain sections of the component 300, regions with higher degrees of foaming can be produced selectively. Non-homogeneous degrees of foaming in the component 300 can also be achieved by a further addition of the filling material 101 during the expansion stroke, by modifying the composition of the filling material during the injection phase or by other suitable measures for influencing the foaming process.
The production of a more complex component having alternate thin- and thick-walled sections 330, with the aid of a mold having two separate expansion mechanisms, is shown below. The mold shown in
As already explained in conjunction with the illustrative embodiment of the method according to the invention described in
As shown in
The production of an integral injection molding with a substantially gradual degree of foaming using a mold comprising three different sliding elements is explained below. In the illustrative embodiment under consideration, the injection mold 100 likewise comprises two shell parts 110, 120, which are joined together, forming an inner cavity 200. In the example under consideration, the three sliding elements 130, 140, 150 are arranged in the upper mold shell 110 although, in principle, they can also be distributed between both shell parts 110, 120. The sliding elements 130, 140, 150 divide the cavity 200 into a total of seven sections 210, 220, 230, 240, 250, 260, 270. By way of example, an injection channel 170 is furthermore shown, opening into the seventh cavity section 270.
In the first method step, the piston-shaped sliding elements 130, 140, 150 are introduced into the cavity 200, it being possible to achieve this by a stroke motion 101 of the sliding elements when the mold shells 110, 120 are assembled. As shown in
In the following method step, the filling compound 301 is injected into the cavity 200 via the injection channel 170. As shown in
Finally, local foaming of the filling material 301 is achieved by retracting the third sliding element 150 in the third component section too. Here, the process can be controlled in such a way that the already foamed filling compound 301 in the first two component sections 310, 320 is also subject to further foaming due to the expansion stroke 150 of the third sliding element 150, which is indicated by means of an arrow 152, leading to a gradually decreasing degree of foaming of the filling compound 301 from the left to the right.
In the method according to the invention, the expansion stroke of the sliding elements can be accomplished either actively by means of corresponding driving devices, passively by means of a pressure produced by a blowing agent added to the filling material or by a combination of both methods. In the case of a passively accomplished expansion stroke, a locking mechanism, which initially blocks the movement of the sliding element, can be used to release the appropriate sliding element at the desired time. The method shown in
As shown in
In the case of a plurality of sliding elements, it is possible to distribute these between both mold halves. In this way, it is possible to facilitate the production of the motion elements, locking mechanisms or mold cooling systems that are required especially in the case of complex geometries.
The embodiments disclosed in conjunction with the figures in the above description are merely illustrative embodiments of the invention. Depending on the use, all the features disclosed in this context may be relevant for the implementation of the invention, either individually or in combination with one another. In particular, any suitable material of an organic or metallic nature can be used as a filling compound, and can contain fillers, reinforcing materials and additives as well. Any suitable blowing gas can be used as a blowing agent, in particular a gas physically released in the molding compound, e.g. nitrogen or carbon dioxide. It is furthermore possible to use a gas or a gas mixture which has formed due to thermal excitation owing to chemical exothermic or endothermic reactions of additives in the molding compound.
The method according to the invention can also be used to produce injection moldings in which one or more inserts are additionally introduced into the cavity and partially or completely overmolded.
In the case of the method according to the invention described in conjunction with the figures, it is also possible for the cavity to be only partially filled with a filling compound and then to be foamed with the aid of an expansion stroke. In this case, the volume available is only partially filled and the empty volume of the cavity is filled by the foaming process of the filling compound.
Number | Date | Country | Kind |
---|---|---|---|
102010038765.7 | Aug 2010 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
---|---|---|---|---|
PCT/EP2011/060301 | 6/21/2011 | WO | 00 | 8/21/2013 |