Abstract
A tool insert for the production of an object by an injection molding method, wherein the injection molding tool includes an insert frame and at least one lamination assembly having a plurality of individual laminations, wherein the at least one lamination assembly is inserted in the insert frame. In further aspects, the invention relates to a method and a system for producing an object having curved surfaces using the tool insert, and to an object which can be produced with the method. The system for producing an object comprises a tool insert and a sliding element. A basic idea of the invention is that curved surfaces can be introduced into the object in that the insert frame has curved surfaces and/or at least one distortion cushion is arranged between the insert frame and the at least one lamination assembly.
Claims
1-12. (canceled)
13. A tool insert for the production of an object by an injection molding method, the tool insert comprising: an insert frame; and at least one lamination assembly having a plurality of individual laminations, the at least one lamination assembly inserted in the insert frame, at least one curved surface introducable into the object in that the insert frame has a curved surface or at least one distortion cushion arranged between the insert frame and the at least one lamination assembly.
14. The tool insert as recited in claim 13 wherein the individual laminations of the lamination assembly have different functionalities imparted by a different microstructuring of the individual laminations.
15. The tool insert as recited in claim 13 wherein differently structured individual laminations are arranged in alternating fashion within the at least one lamination assembly of the tool insert.
16. The tool insert as recited in claim 13 wherein the distortion cushion or the curved surface of the insert frame replicates a surface line of a desired surface of the object.
17. The tool insert as recited in claim 13 wherein the distortion cushion is present and designed to counter any distortions.
18. A method for producing an object having curved surfaces using a tool insert as recited in claim 13, the method comprising: a) providing at least one lamination assembly including a plurality of individual laminations; b) providing an insert frame for receiving the lamination assembly, wherein the insert frame and the lamination assembly form the tool insert; c) introducing a curved surface into the object in that the insert frame has a curved surface or in that at least one distortion cushion is arranged between the insert frame and the at least one lamination assembly.
19. An object produceable with the method as recited in claim 18, the object comprising a basic body and a microstructure on the surface of the basic body, wherein the basic body includes a fiber-reinforced plastic and the microstructure includes a nonreinforced plastic.
20. The object as recited in claim 19 wherein substructures of the microstructure are arranged in rows on the surface of the object, and wherein the substructures are oriented in the rows corresponding to the arrangement of the individual laminations in the lamination assembly.
21. The object as recited in claim 20 wherein a surface of the object is completely covered with the substructures of the microstructure.
22. A system for producing an object, wherein the system comprises: a tool insert as recited in claim 13 and a sliding element, the sliding element having a surface designed as a mating contour to a curved surface of the insert frame.
23. The system as recited in claim 22 wherein the sliding element is designed so as to be movable in an opening of the insert frame.
24. The system as recited in claim 22 wherein the sliding element has a functional surface, wherein the functional surface of the sliding element is designed as a mating contour to a curved surface of the insert frame and is situated opposite to this curved surface of the insert frame during production of the complexly shaped object.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] Identical and similar components are denoted by the same reference signs in the figures, in which:
[0050] FIG. 1 shows a view of a preferred embodiment of a tool insert
[0051] FIG. 2 shows a further view of another preferred embodiment of a tool insert
[0052] FIG. 3 shows the use of a preferred embodiment of the tool insert with distortion cushion
[0053] FIG. 4 shows a view of a preferred embodiment of a grinding plate as an example of a complexly shaped object
[0054] FIG. 5 shows a view of a preferred embodiment of a tool insert
[0055] FIG. 6 shows a view of a preferred embodiment of a Velcro hook with its dimensions.
DETAILED DESCRIPTION
[0056] FIG. 1 shows a preferred embodiment of a tool insert 7. In particular, FIG. 1 shows an insert frame 10 which has a curved surface 13. The individual laminations 11 of the at least one lamination assembly 8 can butt against this curved surface 13 of the insert frame 10 and thus replicate the curved surface 13 of the insert frame 10. As a result, the lamination assembly 8 also has a curved surface and can transmit it to the object 1 to be produced to form a curved surface 12. It is preferred within the meaning of the invention that the curved surface 13 of the insert frame 10 can be designed to be concave or convex. The term concave preferably stands here for a depression which, for example, can be formed as a mountain valley. The term convex preferably stands here for an elevation which, for example, can be formed as a peak of a mountain.
[0057] Moreover, FIG. 1 depicts a sliding element 15 which, together with the tool insert 7, can form a system for producing a complexly shaped object 1. The sliding element 15 has a surface which is designed as a mating contour to a curved surface 13 of the insert frame 10. Moreover, the sliding element 15 can be designed so as to be movable in an opening of the insert frame 10.
[0058] FIG. 2 shows a further preferred embodiment of a tool insert 7. There is illustrated an insert frame 10 which in the left, upper image of FIG. 2 is formed from an upper side 10a and a lower side 10b. It is preferred within the meaning of the invention that the object 1 is formed between the halves of the insert frame 10, in particular by an injection molding method. In the exemplary embodiment of the invention that is illustrated in FIG. 2, the lamination assembly 8, which is formed from a plurality of individual laminations 11, is situated in the insert frame 10. It is preferred within the meaning of the invention that the lamination assembly 8 has a curved surface, wherein this curved surface (here circular) can come about as a result of a curved surface 13 in the insert frame 10 and/or by the provision of a distortion cushion 9 in the insert frame 10. Such a distortion cushion 9 can be seen in particular in FIGS. 2, 3 and 5. The distortion cushion is preferably provided between the lamination assembly 8 and the insert frame 10. The lamination assembly 8, which is illustrated in FIG. 2, is also preferably referred to within the meaning of the invention as a bent lamination assembly 8 since it has at least one curved surface.
[0059] In particular a grinding plate 1 having molded-on Velcro hooks 4 can be produced with the tool insert 7 illustrated in FIG. 2. For the grinding plate 1, it is advantageous if the Velcro hooks 4 (see FIG. 4) are oriented in the circumferential direction. Moreover, it is preferred that the surface 5 (see FIG. 4) of the grinding plate 1 is very planar. The distortion of the grinding plate 1 is, in good approximation, formed rotationally symmetrically. This rotationally symmetrical distortion can be countered by a lamination insert 8 consisting of individual laminations 11 bent substantially in a circular shape and a distortion cushion 9. The distortion cushion 9 can be designed to be conical, straight or rotationally symmetrical. A key advantage of the invention, if it uses the distortion cushion, is that the distortion cushion can assume different conceivable surface shapes. As a result, the method and the tool insert 7 can be used for producing quite different objects and articles. It is very particularly preferred within the meaning of the invention that the surface or its shape can be defined or determined by any desired function of the radius. A corresponding function is preferably identical or substantially identical for all angles of rotation about the center axis.
[0060] A distortion cushion 9 of straight design is illustrated in FIG. 3 in the left image half, whereas a distortion cushion 9 of conical design is illustrated in the right image half. For the iteration of the tool insert 7, all that is required is for the preferably rotationally symmetrically designed distortion cushion 9 to be machined. Advantageously, the surface 5 of the grinding plate 1 correspondingly results through the possibility of the relative movement of the individual laminations 11. The tool insert 7 is fixed, preferably frictionally, by a central clamping mechanism.
[0061] FIG. 3 shows the use of a preferred embodiment of the tool insert 7 with distortion cushion 9. Here, the distortion cushion 9 is used in particular for countering a rotationally symmetrical distortion of the grinding plate 1. FIG. 3 illustrates in particular the grinding plate 1, the bent lamination assembly 8 with its individual laminations 11 and also the distortion cushion 9 of straight or conical design.
[0062] FIG. 4 shows a preferred embodiment of a grinding plate 1, wherein the grinding plate 1 illustrates an example of a preferably complexly shaped object 1, wherein the preferably complexly shaped object 1 can in particular be a grinding plate 1. The grinding plate 1 comprises a basic body 2 and a Velcro hook layer 3 which comprises individual Velcro hooks 4. The Velcro hook layer 3 corresponds to the microstructure 3 of the object 1, whereas the Velcro hooks 4 correspond to the substructures 4. The Velcro hooks 4 are preferably arranged in rows 6 which are arranged between the boundaries of a surface 5 of the grinding plate 1. The rows are preferably so-called radial rows 6 which are arranged at uniform, preferably equidistant spacings from outside to inside on the surface 5 of the grinding plate 1. The Velcro hooks 4 are preferably arranged in radial rows 6, with the Velcro hooks 4 of the radial rows 6 being oriented in an alternating manner in the clockwise direction and in the counterclockwise direction. This allows a particularly strong and robust connection between the grinding plate 1 and a grinding attachment to which the grinding plate 1 can be connected by means of a Velcro fastener connection. In FIG. 4 the Velcro hooks 4 have openings which are oriented in a row 6 with an A orientation for example in the clockwise direction, whereas the openings of the Velcro hooks 4 are oriented in a row 6 with B orientation for example in the counterclockwise direction.
[0063] It is preferred within the meaning of the invention that the surface 5 of the grinding plate 1 functions as an active surface and is of annular design. The basic body 2 of the grinding plate 1 is formed from or comprises a fiber-reinforced plastic, whereas the Velcro hook layer 3 consists of or comprises a nonreinforced plastic.
[0064] FIG. 5 shows a preferred embodiment of a tool insert 7. The tool insert 7 comprises an insert frame 10 and at least one lamination assembly 8. The lamination assembly 8 is formed from individual laminations 11 which, for example, can be inserted into the insert frame 10 in an alternating manner. Between the insert frame 10 and the lamination assembly 8 there can be arranged a distortion cushion 9 for countering any deformations and/or distortions. The individual laminations 11 of the lamination assembly 8 have depressions which are referred to as negative microstructuring 14 within the meaning of the invention. The negative microstructuring 14 is intended to receive the liquid plastic material and to give it its shape during the production process. It is preferred within the meaning of the invention that the negative microstructuring 14 constitutes a negative representation of the Velcro hook layer 3 or the microstructure 3 and molds the latter during the injection molding method.
[0065] FIG. 6 shows a preferred embodiment of a Velcro hook 4 with its dimensions. In particular, FIG. 6 shows the length L, the thickness D and the height H of an exemplary Velcro hook 4. The opening direction or longitudinal direction of the Velcro hooks 4 is illustrated in FIG. 6 by the two-dimensional arrow which points to the right in the figure. The thickness D of the Velcro hooks 4 can also be referred to as width within the meaning of the invention. This thickness D preferably substantially corresponds to the width of a lamination 11 of the lamination assembly 8 minus any shrinkage of the plastic.
LIST OF REFERENCE SIGNS
[0066] 1 Grinding plate or object [0067] 2 Basic body [0068] 3 Velcro hook layer [0069] 4 Velcro hook [0070] 5 Surface of the grinding plate [0071] 6 Radial rows [0072] 7 Tool insert [0073] 8 Lamination assemblies [0074] 9 Distortion cushion [0075] 10 Insert frame [0076] 10a: Upper side [0077] 10b: Lower side [0078] 11 Individual laminations [0079] 12 Curved surface of the object [0080] 13 Curved surfaces in the insert frame [0081] 14 Negative microstructuring of the individual laminations or of the tool insert [0082] 15 Sliding element [0083] L Length of a Velcro hook [0084] D Thickness or width of a Velcro hook [0085] H Height of a Velcro hook
