Disposable Mold Core, Method for Producing a Component and the Component Itself

Abstract

A disposable mold core for producing a fiber-reinforced component includes a support core having a granulate and a binder. The support core has a hard shell formed of the binder and the granulate, and an inner core which is binder-free and formed of the granulate. A related method of producing a fiber-reinforced component is disclosed.

Claims

1. A disposable mold core for producing a fiber-reinforced component, the disposable mold core comprising: a support core including a granulate and a binder, the support core having a hard shell formed of the binder and the granulate, and an inner core which is binder-free and formed of the granulate.

2-27. (canceled)

28. The disposable mold core of claim 1, wherein the granulate includes a base material including at least one of a mineral, a glass, a ceramic, and/or a sand.

29. The disposable mold core of claim 1, wherein the granulate of the inner core is arranged so that individual granulate grains within the inner core lie next to one another.

30. The disposable mold core of claim 1, wherein the support core is configured as a rapid prototyped element.

31. The disposable mold core of claim 30, wherein the rapid prototyped element is a printed element.

32. The disposable mold core of claim 1, wherein a concentration of the binder within the support core decreases in a direction from an outer surface of the support core towards an interior of the support core.

33. The disposable mold core of claim 32, wherein the concentration decreases from 100% to 0%.

34. The disposable mold core of claim 1, wherein the hard shell has a thickness of less than 5 mm.

35. The disposable mold core of claim 1, wherein the mold core has a separating layer which seals off the support core towards an exterior of the support core.

36. The disposable mold core of claim 35, wherein at least one of the binder and the separating layer is dissolvable with a solvent.

37. The disposable mold core of claim 1, wherein the hard shell has at least one opening sized for allowing removal of the inner core therethrough.

38. The disposable mold core of claim 1, wherein the support core includes at least two segments that can be rinsed off with a solvent, and further including a compensatory element arranged between and connecting the two segments to one another in a relatively movable to compensate for misalignment between the two segments.

39. The disposable mold core of claim 38, wherein the compensatory element includes a material that expands when the temperature is increased, so that the two segments can be pressed apart upon heating.

40. The disposable mold core of claim 38, wherein at least one of the binder within the two segments and at least part of the compensatory element can be dissolved with a solvent.

41. A method of producing a fiber-reinforced component comprising the steps of: arranging reinforcement fibers with a matrix on a disposable mold core; at least partially hardening the matrix in a molding tool by increasing at least one of the temperature and pressure; and at least partially removing the disposable mold core.

42. The method of claim 41, wherein the disposable mold core includes a hard shell and a binder-free core, and further including removing the binder-free core from the hard shell.

43. The method of claim 42, further including rinsing the hard shell with a solvent after the binder-free core removed.

44. The method of claim 41, wherein after the at least partially hardening step, while the disposable mold core is still inside the fiber-reinforced component, pressing at least one reinforcement element onto an outer surface of the fiber-reinforced component.

45. The method of claim 44, wherein the reinforcement element is arranged around the disposable mold core with the reinforcement fibers and the matrix before the at least partially hardening step.

46. The method of claim 41, wherein the disposable mold core includes at least two segments, and method further including the step of arranging at least one compensatory element between the at least two segments in such a relatively movable way to compensate for any relative misalignment between the two segments.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Additional advantages of the disclosure are described in the following drawings.

[0053] FIG. 1a is a lateral sectional view of a disposable mold core with a rotational misalignment.

[0054] FIG. 1b is a lateral sectional view of a disposable mold core with a rotational misalignment, two segments and one compensatory element.

[0055] FIG. 1c is a lateral sectional view of a disposable mold core with compensated misalignment.

[0056] FIG. 1d is a lateral sectional view of a disposable mold core in a molding tool.

[0057] FIG. 2 is a lateral sectional view of a section of a disposable mold core and with an articulated joint.

[0058] FIG. 3a is a lateral sectional view of a disposable mold core with a translational misalignment.

[0059] FIG. 3b is a lateral sectional view of a disposable mold core with a compensated translational misalignment.

[0060] FIG. 4 is a lateral sectional view of a component with reinforcement elements.

[0061] FIG. 5 is a lateral sectional view of a component with molding material.

[0062] FIG. 6 is a lateral sectional view of a component with reinforcement elements and fastening elements.

[0063] FIG. 7 is a lateral sectional view of a mold core with a shell.

[0064] FIG. 8 is a lateral sectional view of the mold core with a separating layer.

DETAILED DESCRIPTION

[0065] FIG. 1 shows a disposable mold core 1 to produce a component 15 (cf. FIG. 4) that has a rotational misalignment 4. In this embodiment, the mold core 1 is bent or crooked. Here, the rotational misalignment 4 indicates the misalignment between the mold core 1 according to the form with the dotted line, which indicates that the mold core 1 should have this form, and the form of the actual mold core 1 (crosshatched mold core 1). To illustrate this better, the bend or rotational misalignment 4 is shown here in a highly exaggerated way. It is disadvantageous here that such a bent, crooked mold core 1 having the rotational misalignment 4 will produce a defective component 15.

[0066] In one aspect of the disclosure, the disposable mold core 1 of FIG. 1b includes at least one elastic and/or flexible compensatory element 3 between two segments 2a, 2b of the mold core 1. Naturally, the mold core 1 can also have more segments 2. The compensatory element 3 allows the two segments 2a, 2b to be joined to one another in such a relatively movable way that a translational and/or, as shown here, rotational misalignment 4 can be compensated.

[0067] In this case, the compensatory element 3 has been arranged in a connecting area 7a, 7b of the respective segment 2a, 2b. In this embodiment, the connecting areas 7a, 7b are arranged on the front side, on the respective segments 2a, 2b. Thus, the connection between the two segments 2a, 2b is created by means of the compensatory element 3.

[0068] Here, the mold core 1 can be split, for example, into the two segments 2a, 2b. However, the two segments 2a, 2b can also be manufactured separately.

[0069] In this case, the compensatory element 3 can include an elastomer, for example. As a result of that, the compensatory element 3 is elastic and/or flexible, so that the two segments 2a, 2b are relatively movable towards one another.

[0070] However, the compensatory element 3 can be, additionally or alternately, an unhardened thermoplastic such as a polyvinyl alcohol. Here, the thermoplastic is first heated, introduced in a free space 6 between the segments 2a, 2b by spreading, injecting and/or spraying it (the compensatory element 3 has already been arranged here in the free space 6) and cooled once again, to re-solidify the thermoplastic. This has the advantage that the segments 2a, 2b can be aligned first before the heated thermoplastic is introduced in the free space 6. Also, while the thermoplastic is still hot, the segments 2a, 2b can still be aligned with respect to one another in order to compensate for a translational and/or rotational misalignment 4. The thermoplastic solidifies after cooling, thereby fixing the segments 2a, 2b together in place. In addition, the thermoplastic can be liquefied once again by re-heating it, so the segments 2a, 2b can be aligned one more time and/or the thermoplastic can be rinsed off the component 15 after it is manufactured.

[0071] The compensatory element 3 can also be an unhardened thermoset, which is introduced in the free space 6 like the thermoplastic. In addition, the segments 2a, 2b can be aligned as with the thermoplastic and fixed in place with the thermoset.

[0072] Additionally or alternately, the compensatory element 3 can also be an adhesive that is still elastic and/or flexible in solidified state. Thus, the two segments 2a, 2b can be very easily joined. The adhesive can be spread, sprayed and/or applied on the connecting areas 7a, 7b. Afterwards, the two segments 2a, 2b can be joined together and the adhesive hardens on its own.

[0073] The compensatory element 3 can additionally or alternately also include an expansion material that expands when the temperature is increased. The expansion that takes place while the component 15 is being manufactured presses the two segments 2a, 2b apart in their axial direction. Here, the expansion presses the mold core 1 against an inner side of a molding tool 10 (cf. FIG. 1d), thereby pressing the reinforcement fibers 11 arranged between the mold core and the molding tool 10 against the inner side of the molding tool 10. As a result of this, the component 15 takes an inner form of the molding tool 10. Because of this, however, the play existing between the mold core 1 and the molding tool 10 can also be reduced.

[0074] FIG. 1c shows the disposable mold core 1 from FIG. 1b, but the rotational misalignment 4 of the mold core 1 from FIG. 1b has been compensated. To do this, the elastic and/or flexible compensatory element 3 has been arranged between the two segments 2a, 2b. In addition, the two segments 2a, 2b have been moved relative to one another (compared to FIG. 1b or the dotted contour shown here), so that the rotational misalignment 4 is compensated. In this case, the compensatory element 3 has been stretched in a stretching area 8. The compensatory element 3 can also have, for example, a compression area 9 in which the compensatory element 3 is pressed together. Here, the compensatory element 3 keeps joining the two segments 2a, 2b.

[0075] FIG. 1d shows the disposable mold core 1 in a molding tool 10. Here, the segments 2a, 2b have been joined together in a relatively movable way with the compensatory element 3. In addition, the rotational misalignment 4 (cf. FIG. 1a-1b) has been compensated to compensate for measurement inaccuracies or error tolerances. Reinforcement fibers 11 are arranged between the mold core 1 and the molding tool 10. The reinforcement fibers 11 can be impregnated with a matrix that hardens when the temperature and/or pressure are increased to create the component 15. However, the matrix can also be introduced until the temperature and/or pressure increase. After a cooling phase of the component 15, the matrix has solidified and formed a composite with the reinforcement fibers 11. Thereupon, the component 15 can be taken out of the molding tool 10.

[0076] In order to economize on the weight of the fiber-reinforced component 15, the mold core 1 can be rinsed off the component 15. To do this, a solvent is introduced in the component 15 through an opening (not shown), which dissolves the segments 2a, 2b and the compensatory element 3 so they can be rinsed off afterwards.

[0077] FIG. 2 shows a lateral sectional view of a section of a disposable mold core 1 according to an alternative embodiment. Once again, the elastic and/or flexible compensatory element 3—which firmly joins the two segments 2a, 2b—is arranged between the segments 2a, 2b. Here, the compensatory element 3 has once again been arranged in the free space 6 between the segments 2a, 2b. As seen in FIGS. 1a and 1b, the mold core 1 has a rotational misalignment 4. The dotted lines indicate the mold core 1 without misalignment (as in FIGS. 1a-1b).

[0078] In this alternative embodiment, an articular joint 12 that firmly connects the two segments 2a, 2b is arranged between the two segments 2a, 2b. The articular joint 12 has been designed as two parts, whereby a spherical head 13 is arranged on segment 2a, and a ball socket 14 on segment 2b. In this case, the spherical head 13 is mounted on the ball socket 14, so that both can be twisted against one another. This makes it possible to compensate for the rotational misalignment 4 existing between the two segments 2a, 2b. Here, the spherical head 13 is the connecting area 7a of segment 2a and the ball socket 14 the connecting area 7b of segment 2b.

[0079] Since the articular joint 12 is surrounded by the compensatory element 3, the articular joint 12 becomes elastic. As a result of this, the articular joint 12 is also provided with a certain stability. The free space 6 can also be completely filled with the compensatory element 3.

[0080] FIG. 3a shows a lateral sectional view of a disposable mold core 1 with a translational misalignment 5. Thus, the two segments 2a, 2b are misaligned parallel to one another. Once again, the compensatory element 3, with which the translational misalignment 5 can be compensated and which connects the two segments 2a, 2b, is arranged between the two segments 2a, 2b. In this case, the compensatory element 3 is once more arranged in the free space 6 (shown here filled once again).

[0081] FIG. 3b shows the disposable mold core 1 from FIG. 3a with a compensated translational misalignment 5. Once more, the two segments 2a, 2b are arranged axially with respect to one another. Here, the compensatory element 3 has essentially a shear stress caused by segment 2b being pushed upward against the translational misalignment 5 of FIG. 3a. The compensatory element continues to connect the two segments 2a, 2b.

[0082] FIG. 4 shows an additional aspect of the disclosure. Reinforcement elements 16a-d have been arranged on an outer surface 17 of a component 15. It is problematic to press the reinforcement elements 16a-d onto a hollow component 15 because the component itself 15 can be compressed and therefore damaged. In an additional aspect of the disclosure, the mold core 1 is still arranged in the component 15 while the reinforcement elements 16a-d are being pressed on, so that it cannot be compressed. Only after the reinforcement elements 16a-d have been pressed on will the mold core 1 be rinsed off. In this case, the mold core 1 can have all characteristics of the previous description. In particular, the mold core 1 can also have a described compensatory element 3.

[0083] The reinforcement elements 16a-d can be strengthening ribs and/or a molding material.

[0084] FIG. 5 shows an embodiment, in which the reinforcement element 16 has been pressed onto the outer surface 17 of the component 15. In this embodiment, the reinforcement element 16 is executed as molding material, pressed at least onto areas of the outer surface 17 of the component 15. The molding material can include, for example, a mixture of reinforcement fibers with a matrix. This mixture can be C-SMC, for example. The molding material imparts stability to the component 15 without increasing its dimensions too much. The molding material can be thinly applied here.

[0085] FIG. 6 shows another embodiment of a component 15 with reinforcement elements 16a-d, here executed as strengthening ribs. The reinforcement elements 16a, b, d have fastening elements 27a-e here with which an additional element can be arranged on the component 15 and/or the component 15 itself can be arranged on another element. The fastening elements 27a-d can include sleeves, bores and/or threads or threaded inserts. The fastening element 27e is executed as hook.

[0086] FIG. 7 shows a lateral sectional view of a disposable mold core 1 with a hard shell 22 arranged in a cover area 19. The mold core 1 is developed from a granulate 18 solidified at least partially with a binder. In this embodiment, the binder is only arranged in the cover area 19 that extends from a surface 26 of the mold core 1 towards the core 20 of the mold core 1, so that it forms the shell 22 with the granulate 18. Since the granulate 18 has no binder in the core 20, it is not solidified. Here, the core 20 extends along the middle of a cross section 21 of the mold core 1. The granulate 18 in the core 20 can support the shell 22, so that the surface 26 of the mold core 1 can be impinged on with a pressure without damaging the shell 22. In this case, the granulate 18 can be arranged loose and/or compressed in the core 20. Since the core 20 is not solidified, the granulate 18 can be very easily removed from it or the mold core 1 after the component is manufactured.

[0087] The shell 22 can have here 3% to 10% of the thickness of the mold core 1 at the respective place. The shell 22 can also be less than 5 mm thick. The thickness of the shell 22 can also be less than 2 mm.

[0088] Furthermore, the shell 22 has an opening 23 through which the granulate 18 can be removed from the component 15, especially after the component 15 is manufactured. In particular, due to its own weight, the unsolidified granulate 18 can be very easily trickled out of the opening 23. Once the granulate 18 has been removed, the shell 22 can be rinsed off and/or smashed and removed as well, for example.

[0089] FIG. 8 shows essentially the same mold core 1 shown in FIG. 7, so only the differences will be described here. In this embodiment, the mold core 1 includes a separating layer 24. This separating layer 24 prevents the matrix from diffusing into the mold core 1 or shell 22 while the component is being manufactured. A drawback of this diffusing is that the shell 22 and/or the granulate 18 can no longer be removed from the component or only with great difficulty. The separating layer 24 can prevent this.

[0090] The separating layer 24 has been applied here on the surface 26 of the shell 22.

[0091] Furthermore, the mold core 1 has two reinforcement braces 25a, 25b in this embodiment of FIG. 8. They extend through the mold core 1 from one side of the mold core 1 to the opposite side of the mold core 1. Here, the reinforcement brace 25a extends through the shell 22, thereby reaching from one section of the surface 26 of the mold core 1 to an opposite section of the surface 26. Thus, the shell 22 is adjacent to the reinforcement brace 25a and can be joined to it. On the other hand, the reinforcement brace 25b is arranged on the shell 22 and extends through the granulate 18 between the shell 22.

[0092] The present invention is not limited to the embodiments that were shown and described. Variations within the scope of the patent claims are just as possible as a combination of the characteristics, even if they are shown and described in different embodiments.

LIST OF REFERENCE CHARACTERS

[0093] 1 Disposable mold core [0094] 2 Segment [0095] 3 Compensatory element [0096] 4 Rotational misalignment [0097] 5 Translational misalignment [0098] 6 Free space [0099] 7 Connecting area [0100] 8 Stretching area [0101] 9 Compression area [0102] 10 Molding tool [0103] 11 Reinforcement fibers [0104] 12 Articular joint [0105] 13 Spherical head [0106] 14 Ball socket [0107] 15 Component [0108] 16 Reinforcement element [0109] 17 Outer surface [0110] 18 Granulate [0111] 19 Cover area [0112] 20 Core [0113] 21 Middle of the cross section [0114] 22 Shell [0115] 23 Opening [0116] 24 Separating layer [0117] 25 Reinforcement brace [0118] 26 Surface [0119] 27 Fastening element