Method for producing a component from an organometallic sheet and mould

Abstract

A method for producing a component from a fiber-reinforced thermoplastic material referred to as an organometallic sheet, and which includes an arrangement of fibers embedded in a matrix of a thermoplastic material. To produce the component, the organometallic sheet is thermally shaped and then placed into an injection mold. A mold for carrying out a method for producing a component from a fiber-reinforced thermoplastic material is also provided.

Claims

1. A method for producing a component from a fibre-reinforced thermoplastic material having an arrangement of fibres embedded in a matrix of a thermoplastic material, the method comprising: thermally shaping the fibre-reinforced thermoplastic material; placing the thermally shaped fibre-reinforced thermoplastic material into an injection mould having injection points and at least one mandrel; forming at least one encapsulated clearance in the thermally shaped fibre-reinforced thermoplastic material by placing the injection points in proximity of the at least one encapsulated clearance to be formed, in a manner such that during distribution of the thermoplastic material, an arrangement of fibres of the matrix is widened in dependence on a measured temperature by pushing the at least one mandrel into the fibre-reinforced thermoplastic material at a location of the at least one encapsulated clearance to be formed; wherein the injection points lie at a radial distance of up to 10 cm from the at least one encapsulated clearance to be formed.

2. The method of claim 1, wherein the at least one mandrel is pushed into the fibre-reinforced thermoplastic material during the injection moulding in a direction perpendicularly to a surface of the fibre-reinforced thermoplastic material.

3. The method of claim 1, further comprising, during the forming of the at least one encapsulated clearance: placing inserts on the at least one mandrel; and moulding the inserts onto the fibre-reinforced thermoplastic material in proximity of the at least one encapsulated clearance.

4. The method of claim 1, wherein the at least one encapsulated clearance to be formed lies within a flow path of the injection-moulding material.

5. The method of claim 1, wherein the forming of the at least one encapsulated clearance is performed in a time-correlated manner with the introduction of the injection-moulding material by moving in the at least one mandrel on slides of the injection mould.

6. The method of claim 5, wherein the pushing of the mandrels is performed in dependence on a temperature signal of a temperature sensor.

7. The method of claim 6, wherein the measured temperature at the sensor is to exceed a minimum temperature in order to allow movement of the mandrel.

8. The method of claim 1, wherein the fibre-reinforced thermoplastic material comprises an organometallic sheet.

9. A method for producing a component, the method comprising: thermally shaping a fibre-reinforced thermoplastic material having an arrangement of fibres embedded in a matrix of a thermoplastic material; placing the thermally shaped fibre-reinforced thermoplastic material into an injection mould having injection points and at least one mandrel; forming at least one clearance in the thermally shaped fibre-reinforced thermoplastic material, by placing the injection points in proximity of the at least one clearance to be formed, in a manner such that during distribution of the thermoplastic material, an arrangement of fibres of the matrix is widened in dependence on a measured temperature by pushing the at least one mandrel into the fibre-reinforced thermoplastic material at a location of the at least one clearance to be formed; wherein the injection points lie at a radial distance of up to 10 cm from the at least one encapsulated clearance to be formed.

10. The method of claim 9, wherein the at least one mandrel is pushed into the fibre-reinforced thermoplastic material during the injection moulding in a direction perpendicularly to a surface of the fibre-reinforced thermoplastic material.

11. The method of claim 9, further comprising, during the forming of the at least one encapsulated clearance: placing inserts on the at least one mandrel; and moulding the inserts onto the fibre-reinforced thermoplastic material in proximity of the at least one encapsulated clearance.

12. The method of claim 9, wherein the at least one encapsulated clearance to be formed lies within a flow path of the injection-moulding material.

13. The method of claim 9, wherein the forming of the at least one encapsulated clearance is performed in a time-correlated manner with the introduction of the injection-moulding material by moving in the at least one mandrel on slides of the injection mould.

14. The method of claim 13, wherein the pushing of the mandrels is performed in dependence on a temperature signal of a temperature sensor.

15. The method of claim 14, wherein the measured temperature at the sensor is to exceed a minimum temperature in order to allow movement of the mandrel.

16. The method of claim 9, wherein the fibre-reinforced thermoplastic material comprises an organometallic sheet.

Description

DRAWINGS

(1) Embodiments will be illustrated by way of example in the drawings and explained in the description hereinbelow.

(2) FIG. 1 illustrates a schematic representation of the method, in accordance with embodiments.

(3) FIG. 2 illustrates a schematic representation of the method, in accordance with embodiments.

(4) FIG. 3 illustrates a schematic representation of the method, in accordance with embodiments.

(5) FIG. 4 illustrates a plan view of an organometallic sheet, in accordance with embodiments.

DESCRIPTION

(6) FIG. 1 illustrates a first step of the method for producing a component from a fibre-reinforced thermoplastic material referred to as an organometallic sheet. An organometallic sheet 1 is schematically represented. The pre-formed organometallic sheet blanks includes fibre scrims that are impregnated with a plastics material. The blanks may, in this case, take any form desired and may be adapted to the product. After placing the blank into the lower part 2 of a thermoforming mould, the thermoforming mould is closed by its upper part 3 moving in the direction a. By heating the blank with its plastic-impregnated matrix, the organometallic sheet 1 is brought into a three-dimensional shape. Subsequently, the organometallic sheet 1 is removed from the thermoforming mould, once the upper part 3 of the thermoforming mould has been moved upwards in the direction b.

(7) As illustrated in FIG. 2, another injection mould, in accordance with embodiments, includes upper part 4 and lower part 5. The three-dimensionally shaped organometallic sheet blank 1 is placed into the injection mould. It may be seen that the lower part 5 of the injection mould is provided with mandrels 6, which may penetrate through the surface of the lower part 5 and move in the direction b relative to the lower part 5. The upper part 4 of the injection mould has injection runners 7.

(8) As illustrated in FIG. 3, the injection mould of FIG. 2 is in a closed state. Mandrels 6 are connected to slides 11, which may be displacable vertically relative to the lower mould part 5 (in the direction b). The left-hand mandrel 6 exhibits an insert 10, which is centred by the mandrel 6. A temperature sensor 12 is arranged in spatial proximity to the mandrel 6.

(9) After the closing of the injection mould 4, 5, an injection space is created therein. Injection-moulding material is forced into the cavity via the injection runners 7 in the direction c relative to the upper mould part 4.

(10) In accordance with a first embodiment, after the beginning of the injection, a predetermined time t.sub.hold is left before the slides 11 are activated and the mandrels 6 are pushed into the organometallic sheet 1. In this case, the time t.sub.hold is chosen such that the matrix of the organometallic sheet 1 melts, and the introduction of the mandrels 6 is thus facilitated.

(11) In accordance with another embodiment, the temperature sensor 12 is provided and which is to measure the temperature at a position in close proximity to the mandrels 6. When a temperature threshold t.sub.s is reached, the associated slide 11 is actuated and the mandrel 6 is moved in the direction of the organometallic sheet 1. It is also conceivable that a number of temperature sensors 12 may be used, respectively arranged adjacent to the mandrels 6.

(12) The pushed-in mandrels 6 remain in the organometallic sheet 1 and are thus flowed around by the injection-moulding material. Only when the material has cooled down are the mandrels 6 withdrawn and the mould is opened.

(13) It is also possible that the mandrels 6 are used to encapsulate further inserts 10, including on the upper side 20. For this purpose, the mandrels remain in their position as they penetrate the organometallic sheet 1, and thereby form a suitable centring point for the insertion of further components into the mould. The organometallic sheet 1 may subsequently be encapsulated once again.

(14) As illustrated in FIG. 4, a plan view of the organometallic sheet 1 has a pair of clearances 8, injection points 9 lying adjacent to the clearances 8. The injection points 9 in this case lie, for example, within a radial distance of less than 10 cm. However, such a restriction is not absolutely necessary, as long as injection-moulding material may flow over the place to be penetrated. In the case of a lateral runner, the mandrel 6 must be moulded in immediately after the flow front of the injected material comes to a standstill. With suitable component geometry, the distance between the injection point 9 and the clearance 8 may also be greater if a direction of flow of the plastics material that extends in the direction of the clearance is prescribed. In FIG. 4, two softening regions 13 are illustrated, on the one hand, extending circularly around the injection point 9, and on the other hand, following a direction of flow.

(15) The term coupled or connected may be used herein to refer to any type of relationship, direct or indirect, between the components in question, and may apply to electrical, mechanical, fluid, optical, electromagnetic, electromechanical or other connections. In addition, the terms first, second, etc. are used herein only to facilitate discussion, and carry no particular temporal or chronological significance unless otherwise indicated.

(16) Those skilled in the art will appreciate from the foregoing description that the broad techniques of the embodiments may be implemented in a variety of forms. Therefore, while the embodiments have been described in connection with particular examples thereof, the true scope of the embodiments should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification, and following claims.

LIST OF REFERENCE SIGNS

(17) 1 Organometallic sheet

(18) 2 Lower part of thermoforming mould

(19) 3 Upper part of thermoforming mould

(20) 4 Upper part of injection mould

(21) 5 Lower part of injection mould

(22) 6 Mandrel

(23) 7 Injection runner

(24) 8 Clearance

(25) 9 Injection point

(26) 10 Insert

(27) 11 Slide

(28) 12 Temperature sensor

(29) 13 Softening region

(30) 20 Upper side

(31) a Direction of insertion

(32) b Direction of removal

(33) c Direction of injection