DEVICE AND METHOD FOR THE MASS PRODUCTION OF AT LEAST PARTIALLY FIBER-REINFORCED INJECTION MOLDED PARTS

Abstract

A device for production of at least partially fiber-reinforced injection molded parts includes at least one injection molding tool, with at least one first tool part and at least two second tool parts that can be selectively connected to the first tool part in order to form an injection molding cavity. The device also includes at least one placement unit, at least one injection unit and at least one electronic control. The at least one placement unit automatically places at least one tape section of a fiber-reinforced plastic tape on a cavity section of one of the second tool parts or on an injection molded workpiece disposed on said cavity section. The at least one injection unit injects a molding compound into the respective injection molding cavity and the at least one electronic control controls the placement unit and the injection unit.

Claims

1. A device for production of at least partially fiber-reinforced injection molded parts comprising: at least one injection molding tool, which comprises at least one first tool part and at least two second tool parts that are selectively connected to the first tool part in order to form an injection molding cavity; at least one placement unit for automatically placing at least one tape section of a fiber-reinforced plastic tape on a cavity section of one of the second tool parts or on an injection molded workpiece disposed on said cavity section; at least one injection unit for injecting a molding compound into the injection molding cavity; and at least one electronic control to control the placement unit and the injection unit, wherein the electronic control is configured to activate the placement unit during at least one of injection of the molding compound into the respective injection molding cavity and cooling of the molding compound injected into said injection molding cavity.

2. The device according to claim 1, wherein the two second tool parts are disposed on mutually opposing sides of a holding unit holding the two second tool parts, wherein a distance between the first tool part and the holding unit can be varied along a linear path of movement and the holding unit is rotatably disposed about a rotary axis oriented transversely to the linear path of movement.

3. The device according to claim 2, wherein the injection molding tool comprises at least one third tool part disposed on a side of the holding unit lying opposite to the first tool part, which can be selectively connected to one of the second tool parts in order to form an injection molding cavity, wherein a distance between the third tool part and the holding unit can be varied along a linear path of movement, and four second tool parts that are uniformly circumferentially spaced with respect to each other on the holding unit about the rotary axis, wherein the placement unit is configured in a manner such that, during injection of the molding compound into the two injection molding cavities between the respective second tool parts on the one hand and the first tool part or the third tool part on the other hand and/or during cooling of the molding compounds injected into the two injection molding cavities, at least one tape section of the fiber-reinforced plastic tape is placed on the respective two second tool parts that are not connected to the first tool part or to the third tool part.

4. The device according to claim 1, wherein the cavity section of at least one of the second tool parts is provided, at least in regions, with a chemically and/or physically treated surface in order to improve its adhesive properties.

5. The device according to claim 1, wherein the placement unit comprises at least one supply unit to supply the fiber-reinforced plastic tape, at least one compaction roller for progressive compaction of a tape section of the fiber-reinforced plastic tape that is progressively removed from the supply unit, and at least one laser source for irradiation of an advancing connecting region between the tape section and the cavity section of the respective second tool part or the injection molded workpiece disposed on the cavity section.

6. A method for production of at least partially fiber-reinforced injection molded parts comprising: injection molding a plurality of an at least partially fiber-reinforced injection molded parts using an injection molding tool with at least one first tool part and at least two second tool parts selectively connected to the first tool part in order to form an injection molding cavity, wherein at least one tape section of a fiber-reinforced plastic tape is automatically placed on a cavity section of the other of the second tool parts or on an injection molded workpiece disposed on the cavity section during at least one of injection of a molding compound into the injection molding cavity formed with one of the second tool parts and cooling of the molding compound injected into the injection molding cavity.

7. The method according to claim 6, wherein the at least one tape section is progressively placed on the cavity section of the respective second tool part or the injection molded workpiece disposed on the cavity section, wherein at least one of a section in front of an advancing connecting region of the at least one tape section, the cavity section and the injection molded workpiece is heated.

8. The method according to claim 7, wherein a surface of the cavity section of at least one of the second tool parts is treated chemically and/or physically prior to the placement of the tape section of the fiber-reinforced plastic tape in order to improve the adhesive properties of the surface.

Description

DRAWINGS

[0045] In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:

[0046] FIG. 1 shows a schematic representation of an exemplary form of a device, according to the teachings of the present disclosure;

[0047] FIG. 2 shows a schematic representation of a second tool part of a further exemplary form of a device, according to the teachings of the present disclosure;

[0048] FIG. 3 shows a schematic representation of a placement unit of a further exemplary form of a device, according to the teachings of the present disclosure; and

[0049] FIG. 4 shows a flow diagram of an exemplary form of a method, according to the teachings of the present disclosure.

[0050] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

[0051] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. Examples are provided to fully convey the scope of the disclosure to those who are skilled in the art. Numerous specific details are set forth such as types of specific components, devices, and methods, to provide a thorough understanding of variations of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed and that the examples provided herein, may include alternative forms and are not intended to limit the scope of the disclosure. In some examples, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0052] Referring to FIG. 1, a form of the present disclosure is shown, a schematic representation of an exemplary form of a device 1 in accordance with the present disclosure for the mass production of at least partially fiber-reinforced injection molded parts (not shown).

[0053] The device 1 comprises an injection molding tool 2 which comprises a first tool part 3 and four second tool parts 4 which can be selectively connected with the first tool part 3 in order to form an injection molding cavity (not shown). In each case, two of the second tool parts 4 are disposed on mutually opposing sides of a holding unit 5 which holds or forms the four second tool parts 4. A distance between the first tool part 3 and the holding unit 5 can be varied along a linear path of movement which is indicated by the double-headed arrow 6. The holding unit 5 is rotatably disposed about a rotary axis 7 oriented transversely to the linear path of movement.

[0054] In addition, the injection molding tool 2 comprises a third tool part 8 disposed on a side of the holding unit 5 lying opposite to the first tool part 3, which can be selectively connected to one of the second tool parts 4 in order to form an injection molding cavity (not shown). A distance between the third tool part 8 and the holding unit 5 can be varied along the linear path of movement. The second tool parts 4 are uniformly circumferentially spaced with respect to each other on the holding unit 5 about the rotary axis 7.

[0055] Furthermore, the device 1 comprises at least one injection unit 9 for injecting a molding compound into the respective injection molding cavity. Two mutually opposing injection units 9 can be seen, by way of example.

[0056] In addition, the device 1 comprises at least one placement unit (not shown) for automated placement of at least one tape section (not shown) of a fiber-reinforced plastic tape (not shown) on a cavity section 10 of one of the second tool parts 4 or on an injection molded workpiece (not shown) disposed on said cavity section 10. The placement unit may, for example, be configured in accordance with FIG. 3. The cavity section 10 of at least one of the second tool parts 4 may be provided with a chemically and/or physically treated surface (not shown) in order to improve its adhesive properties.

[0057] Furthermore, the device 1 comprises an electronic control 11 to control the placement unit and the injection unit 9. The electronic control 11 is configured in a manner such that the placement unit is activated during injection of the molding compound into the respective injection molding cavities and/or during cooling of the molding compound injected into these injection molding cavities. During injection of the molding compound into the two injection molding cavities between the respective second tool parts 4 on the one hand and the first tool part 3 or the third tool part 8 on the other hand and/or during cooling of the molding compounds injected into the two injection molding cavities, the placement unit is configured to respectively place at least one tape section of the fiber-reinforced plastic tape onto the respective two second tool parts 4 that are not connected to the first tool part 3 or to the third tool part 8.

[0058] The placement unit may comprise at least one supply unit (not shown) to supply the fiber-reinforced plastic tape, at least one compaction roller (not shown) for progressive compaction of a tape section of the fiber-reinforced plastic tape that is progressively removed from the supply unit, and at least one laser source (not shown) for irradiation of an advancing connecting region between the tape section and the cavity section 10 of the respective second tool part 4 or the injection molded workpiece disposed on the cavity section 10.

[0059] Now referring to FIG. 2, another form of the present disclosure is shown, a schematic representation of a second tool part 12 of a further exemplary form of a device 13 in accordance with the present disclosure for the mass production of at least partially fiber-reinforced injection molded parts (not shown). The device 13 may otherwise be configured in accordance with the exemplary form shown in FIG. 1.

[0060] The cavity section 14 of the second tool part 12 is shown, on which a tape section 15 of a fiber-reinforced plastic tape (not shown) is disposed. The cavity section 14 is connected to the tape section by the placement unit (not shown) of the device 13 in a manner such that no additional fixing is desired to fix the tape section to the cavity section 14. In this regard, the cavity section 14 is provided, at least in regions, with a chemically and/or physically treated surface in order to improve its adhesive properties.

[0061] Referring now to FIG. 3, yet another form of the present disclosure is shown, a schematic representation of a placement unit 16 of a further exemplary form of a device 17 in accordance with the present disclosure for the mass production of at least partially fiber-reinforced injection molded parts (not shown). The device 17 may otherwise be configured in accordance with the exemplary form shown in FIG. 1.

[0062] The placement unit 16 comprises at least one supply unit (not shown) to supply the fiber-reinforced plastic tape 18, at least one compaction roller 19 for progressive compaction of a tape section 20 of the plastic tape 18 that is progressively removed from the supply unit, and at least one laser source 21 for irradiation of an advancing connecting region between the tape section 20 and the cavity section 22 of the respective second tool part 23 or the tape section 20 that is already disposed on the cavity section 22, using a laser beam 24. Further, FIG. 3 shows that a fourth tape section 20 has already been placed in this manner using the placement unit 16.

[0063] Referring to FIG. 4, one form of the present disclosure is shown, a flow diagram of an exemplary form of a method in accordance with the present disclosure for the mass production of at least partially fiber-reinforced injection molded parts using an injection molding tool with at least one first tool part and at least two second tool parts that can be selectively connected to the first tool part in order to form an injection molding cavity.

[0064] In step 100 of the method, a surface of the cavity section of at least one of the second tool parts is treated chemically and/or physically at least in regions prior to the placement of the tape section of the plastic tape in order to improve its adhesive properties. The step 100 of the method is stored for efficient production and for one run, it is expediently only carried out once.

[0065] In step 200 of the method, during injection of the molding compound into the injection molding cavity respectively formed with one of the second tool parts and/or during cooling of the molding compound injected into said injection molding cavity, at least one tape section of a fiber-reinforced plastic tape is automatically placed on a cavity section of the other of the second tool parts or on an injection molded workpiece disposed on said cavity section. In this regard, the tape section is progressively placed on the cavity section of the respective second tool part or the injection molded workpiece disposed on the cavity section, wherein a section in front of the thus-advancing connecting region of the tape section on the one hand and of the cavity section or the injection molded workpiece on the other hand is heated.

REFERENCE LIST

[0066] 1 device; [0067] 2 injection molding tool; [0068] 3 first tool part; [0069] 4 second tool part; [0070] 5 holding unit; [0071] 6 double-headed arrow (linear path of movement); [0072] 7 rotary axis of 5; [0073] 8 third tool part; [0074] 9 injection unit; [0075] 10 cavity section of 4; [0076] 11 electronic control; [0077] 12 second tool part; [0078] 13 device; [0079] 14 cavity section of 12; [0080] 15 tape section; [0081] 16 placement unit; [0082] 17 device; [0083] 18 plastic tape; [0084] 19 compaction roller; [0085] 20 tape section; [0086] 21 laser source; [0087] 22 cavity section of 23; [0088] 23 second tool part; [0089] 24 laser beam; [0090] 100 step of method (surface treatment); and [0091] 200 step of method (injection molding and placement).

[0092] When an element or layer is referred to as being on or thereon another element or layer, it may be directly on the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being directly on or directly thereon another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in like fashion (e.g., between versus directly between, adjacent versus directly adjacent, etc.). As used herein, the term and/or includes any and all combinations of one or more of the associated listed items.

[0093] Although the terms first, second, third, etc. may be used to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections, should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer and/or section, from another element, component, region, layer and/or section. Terms such as first, second, and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section, could be termed a second element, component, region, layer or section without departing from the teachings of the example forms. Furthermore, an element, component, region, layer or section may be termed a second element, component, region, layer or section, without the need for an element, component, region, layer or section termed a first element, component, region, layer or section.

[0094] Spacially relative terms, such as below, lower, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as below or beneath other elements or features would then be oriented above the other elements or features. Thus, the example term below can encompass both an orientation of above or below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0095] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean at least one of A, at least one of B, and at least one of C.

[0096] Unless otherwise expressly indicated, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word about or approximately in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, manufacturing technology, and testing capability.

[0097] The terminology used herein is for the purpose of describing particular example forms only and is not intended to be limiting. The singular forms a, an, and the may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms including, and having, are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0098] The description of the disclosure is merely exemplary in nature and, thus, examples that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such examples are not to be regarded as a departure from the spirit and scope of the disclosure. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims.