AT526872B1 - Forming machine for manufacturing molded parts - Google Patents

Abstract

Molding machine (1), in particular injection molding machine, for producing molded parts, in particular composite molded parts, from at least one molding compound (7) and an additive (9), comprising: at least one first molding cylinder (2) and a second molding cylinder (3), at least one connecting line (4) between the at least two molding cylinders, wherein the connecting line (4) directs the flow direction (5) of the plasticizing stream from the first molding cylinder (2) to the second molding cylinder (3), at least one molding hopper (6) for receiving at least one molding compound (7) and/or at least one additive, wherein the at least one molding hopper (6) is connected to the first molding cylinder (2), and at least one injection point (8) for receiving at least one molding compound and/or at least one additive (9), wherein at least one metering device is arranged upstream of the at least one molding hopper (6) and/or the at least one injection point (8), wherein the at least one metering device arranged upstream of the at least one molding hopper (6) and/or the at least one injection point (8) is configured to is, which supplies at least one molding compound (7) and/or at least one additive (9) to at least one mass hopper (6) and/or at least one addition point (8), and at least one drying device (17) and/or at least one crystallizer (17) is provided.

Description

Ss N

Description

[0001] The present invention relates to an injection molding machine according to the features of the preamble of claim 1 and to a method using such an injection molding machine.

[0002] In the field of forming processes, two-stage processes are already state of the art. These typically involve the use of two or more cylinders to process the forming compound and thus produce molded parts. In contrast to single-stage processes, this offers several advantages, such as a more homogeneous forming compound, which consequently leads to higher quality molded parts.

[0003] In the following, a 2-stage process of a forming machine is understood to be a forming process in which a single forming machine has at least two ingot cylinders. Preferably, the at least two ingot cylinders are connected in series in terms of fluid flow.

[0004] As concrete examples, in the course of a 2-stage process of a forming machine, two screw presses for continuous extrusion or two melt cylinders, one of which is an injection unit, can be used for injection molding.

[0005] “Fluidally connected in series” here means that a plasticizing current is directed from a first mass cylinder to a second mass cylinder. The fluid connection can directly or indirectly connect the at least two mass cylinders. It can therefore be provided that the plasticizing current is directed from a first mass cylinder directly into a second mass cylinder. However, it can also be provided that a component is located between the at least two mass cylinders, such as a connecting line and/or other components.

[0006] Although a 2-stage process must have at least two mass cylinders, the number of mass cylinders involved in the 2-stage process can be freely chosen. For example, three mass cylinders can be provided, all three connected one after the other and thus in series from a fluid dynamics perspective. However, it is also conceivable that a first mass cylinder and a second mass cylinder each introduce their own plasticizing flow into a third mass cylinder, with the two plasticizing flows of the first and second mass cylinders being combined into a common plasticizing flow in the third mass cylinder.

[0007] The prior art includes, for example, US 5,253,994 A. Here, two batch cylinders are used, wherein a recycled material is plasticized in a first batch cylinder, conveyed through a filter in a connecting line, and then transferred to a second batch cylinder. In the second batch cylinder, the recycled material can be mixed with virgin material and plasticized homogeneously. In this way, a material for a molded part can be provided from a proportion of recycled material and a proportion of virgin material.

[0008] Further prior art documents are DE 10012532 A1, US 5165941 A and US 2006191423, which disclose forming machines in a 2-stage process, with DE 10012532 A1 disclosing a forming machine with an addition point, a metering device, a drying device and a mixing screw.

[0009] However, the following disadvantageous situation arises with the prior art.

[0010] The use of two or more mass cylinders severely limits the flexibility in influencing the overall process. Due to the high demands of a two-stage process, a forming machine designed and fully installed for a specific two-stage process can only be used for a limited range of applications. As soon as the requirements for the materials used in the forming compounds or additives, or for the molded parts to be produced, change, existing two-stage processes and the forming machines required for them quickly reach their limits.

[0011] Although there are several possibilities for sequential single-stage processes

Ss Ss

Ss N

Sr 'hes AT 526 872 B1 2025-12-15

While it is possible to flexibly influence the processes, such compounding methods result in higher stresses on the materials being processed.

[0012] In processes with several consecutive single-stage processes, the material can, for example, first be filtered. An extruder and a filter can be used for this purpose. Subsequently, the material is granulated before being compounded in a further single-stage process. Following compounding, the material is granulated again, and then a shaping process can follow.

[0013] Several consecutive single-stage processes result in considerable damage to the material due to repeated heating, cooling, transport between the individual single-stage processes and/or granulation or comminution of the material to be processed.

[0014] The object of the present invention is therefore to at least partially overcome the disadvantages of the prior art and to provide an improved injection molding machine compared to the prior art, which is characterized in particular by increased influence on a 2-stage forming process with gentle compounding. The object is further to specify a method using such an improved injection molding machine.

[0015] This problem is solved by the features of claims 1 and 10.

[0016] With regard to the present invention, this is solved by the features of claim 1, namely by providing an injection molding machine for producing molded parts, in particular composite molded parts made of at least one molding compound and an additive, with:

- at least one first mass cylinder and one second mass cylinder,

- at least one connecting line between the at least two mass cylinders, wherein the connecting line directs the flow direction of the plasticizing current from the first mass cylinder to the second mass cylinder,

- at least one mass funnel for receiving molding compound, wherein the at least one mass funnel is connected to the first mass cylinder, and

- at least one addition site for at least one additive, wherein

- at least one metering device is connected upstream of at least one hopper and/or at least one addition point, wherein the at least one metering device connected upstream of at least one hopper and/or at least one addition point is designed to supply at least one molding compound and/or at least one additive to at least one hopper and/or at least one addition point, and

- at least one drying device and/or at least one crystallizer is provided,

where

- which provides at least one addition point for the at least one additive, wherein the at least one addition point is arranged in the second mass cylinder, preferably in the flow direction of the plasticizing stream in the area before and/or after the transition of the connecting line into the second mass cylinder and/or in the flow direction of the plasticizing stream in the area of the end of the second mass cylinder, and

- a mixing screw is provided, wherein the mixing screw o is arranged in the second mass cylinder and

o and has a mixing zone, wherein a mixer of the mixing zone is designed as a shearing element, as a maddock, as a shear-mixing element and/or as a toothed disc mixing element, and

- where an embossing tool is provided.

[0017] By providing a metering device, the addition of additives to a molding compound for the production of a molded part can be simplified and improved. A metering device allows the addition to be synchronized with the delivery rate of the plasticized molding compound, meaning that the mixture of molding compound and additive can be controlled and/or regulated, and/or it can be automated.

[0018] When using an embossing tool as a forming tool in an injection molding machine during an injection compression molding process, damage to additives, particularly in the form of fibers, granules such as long glass fiber granules (LFG granules), filaments, rovings, fabrics and/or non-woven fabrics, can be reduced. The reduction of such additive damage can be significant compared to conventional injection molds.

[0019] A dosing device can be connected to a control and/or regulating unit, wherein the control and/or regulating unit can include an input unit, a computing unit, an output unit and/or a storage unit.

[0020] The control and/or regulating unit can be designed to control and regulate the dosed amount of additive and/or molding compound.

[0021] The control and/or regulating unit can be operated locally, for example via an operating unit, or remotely controlled, for example via a wired or wireless connection to a control device. All technologies such as LAN, WLAN or other network technologies are conceivable for this purpose.

[0022] Depending on the requirements for the molded part to be produced, one or more additives can be added to one or more molding compounds by means of the dosing device before the molding compounds and additives are homogenized and then formed by the same machine.

[0023] By providing at least one drying device and/or at least one crystallizer in addition to the metering device, the material to be processed is prepared in a mixing cylinder before processing. For this purpose, a drying device can dry the material to be processed and/or a crystallizer can prevent the material to be processed from clumping.

[0024] In a particularly preferred embodiment, long glass fiber granules (LGF granules) can be added. The molding compound can be added as the base material to a first cylinder via a hopper and plasticized. The long glass fiber granules (LGF granules) can then be added to the second cylinder via an injection point. The screw of the second cylinder can be designed to be particularly gentle in order to avoid damaging the long glass fiber granules (LGF granules) as much as possible. In this way, significantly longer fiber lengths can be achieved than with an LGF screw in a single-stage process.

[0025] The mixing screw has a mixing zone. The mixing screw and/or the mixing zone can be designed differently, for example as a shearing section, maddock, shear-mixing section or toothed disc mixing section.

[0026] A mixing zone is that area of the screw in which special mixing elements are provided on the screw, thereby increasing the mixing performance. This is particularly important for homogeneous mixing of additives. There can be more than one mixing zone along a screw.

[0027] A drying device is a device designed to dry molding compound and/or additives.

[0028] A crystallizer is a device designed to prevent or at least reduce clumping of molding compound and/or additives.

It's AT 526 872 B1 2025-12-15

Ss N

[0029] A crystallizer can dry molding compound and/or additives to achieve low moisture levels, whereby the low moisture content of the material leads to less degradation.

[0030] Especially when recycled material is used in a 2-stage process, a prior washing process of the recycled material is often necessary. A forming machine for a 2-stage process with a dosing device and a drying device and/or a crystallizer allows for increased control over the 2-stage forming process while simultaneously ensuring gentle compounding.

[0031] Forming machines can include injection molding machines, injection presses, presses and the like. Forming machines in which the plasticized mass is fed into an open mold are also conceivable.

[0032] Particularly preferably an injection molding machine is provided which is intended for injection molding and/or injection compression molding.

[0033] An additive is generally understood to be any type of additive that is added to a base substance.

[0034] In preferred embodiments, the base material can represent the molding compound and constitute the main proportion of the mass to be processed, measured by volume and/or weight percent.

[0035] An additive can be added in various forms, for example in the form of fibers, powder, granules, in particular long glass fiber granules (LGF granules), filaments, rovings, fabrics and/or nonwovens.

[0036] An additive can consist of various materials. For example, an additive can comprise a reinforcing material in the form of glass fibers and/or carbon fibers. However, it is also conceivable that the additive constitutes a second molding compound; for example, two different types of plastic can be used, with the molding compound representing the first type of plastic and the additive the second type of plastic. The additive can also be another type of additive, such as a pigment.

[0037] It is also conceivable that the additive and the molding compound represent the same material. The additive can represent the same material in the form of a recycled material, and the molding compound can represent the same material in the form of a virgin material, and vice versa. This is particularly useful when materials such as rPET are reused and recycled.

[0038] The number of additives added is not limited; for example, different additives such as reinforcing materials and other molding compounds can be added during the same molding process.

[0039] A device according to the invention can be used in previously known embodiments of the prior art, such as those disclosed in this description, and can be subsequently installed.

[0040] Further advantageous embodiments of the arrangement are defined in the dependent claims.

[0041] According to a preferred embodiment of the injection molding machine, the first melt cylinder is a plasticizing unit with at least one plasticizing screw and/or the second melt cylinder is an injection unit with at least one injection screw.

[0042] A plasticizing unit is a device with a screw for plasticizing and/or melting a molding compound and/or additives. Such a plasticizing unit can receive the molding compound, usually in the form of granules, via an inlet opening, for example a hopper, and convey the molding compound, usually in the form of a plasticized and/or melted mass, via an outlet opening.

It's AT 526 872 B1 2025-12-15

Ss N

[0043] In a simple embodiment, the plasticizing unit is a screw extruder with a plasticizing screw.

[0044] Plasticizing screws are rotatably mounted and driven within the melt cylinder. Plasticizing screws can also be arranged to be axially displaceable within the melt cylinder. The plasticized and/or molten material can be conveyed further, preferably into a connecting line or into another melt cylinder, by the rotational movement and/or the axial displacement of the plasticizing screw.

[0045] An injection unit is a device for injecting a molding compound and/or an additive into a molding tool under a specific, preferably increased, pressure.

[0046] An injection unit can simultaneously be a plasticizing unit. In such a case, the plasticizing unit or the injection unit includes an injection screw, wherein the injection screw can be rotatably and axially displaceably arranged in the melt cylinder. In other words, the injection screw can be a push screw. An injection unit with an injection screw can perform both the plasticizing and/or melting as well as the injection of a molding compound and/or an additive into a molding tool.

[0047] According to a preferred embodiment of the injection molding machine, it is provided that the at least one addition point is provided for the at least one additive, preferably for fibers, powder and/or granules, particularly preferably for long glass fiber granules (LGF granules), wherein the addition point

- in the first mass cylinder, preferably in the area before the transition of the first mass cylinder into the connecting line, and/or

- in the connecting line between the at least two mass cylinders, preferably in the area before the transition of the connecting line into the second mass cylinder,

is arranged. [0048] There is a need for the metered addition of additives such as fibers or powders.

[0049] For bulk materials such as small fibers or powders that do not cause pressure build-up, an addition point can preferably be provided initially in the flow direction, for example in the first melt cylinder and/or in the connecting line. Such bulk materials can then come into contact with the plasticized melt or the plasticizing stream through the feeding rate of a metering device. The plasticizing stream can then carry the additives, i.e., the aforementioned bulk materials, and subsequently, one or more screws can homogeneously incorporate the additives into the plasticizing stream.

[0050] The addition point to be used and its position within the injection molding machine depends on the quantity and type of additives to be added. It may be advantageous to provide several addition points in the injection molding machine in order to achieve different levels of additive feeding and/or the addition of different additives in one or more molding processes.

[0051] In a particularly preferred embodiment, a mixing screw may be provided, wherein the mixing screw

- a plasticizing screw or an injection screw.

[0052] According to a preferred embodiment of the injection molding machine, the at least one metering device is a comminution device, wherein the comminution device is located upstream of the at least one material hopper and/or the at least one addition point, wherein the comminution device located upstream of the at least one material hopper and/or the at least one addition point is designed to comminute the at least one molding compound and/or the at least one additive and to feed the at least one comminution of the molding compound and/or the at least one comminution of the additive to the at least one material hopper and/or the at least one addition point.

It's AT 526 872 B1 2025-12-15

Ss N

[0053] Because the dosing device is a comminution device, at least one additive can be comminuted to a desired size during controlled dosing and added to the plasticizing stream.

[0054] According to a preferred embodiment of the injection molding machine, the comminution device is a cutting device, wherein the cutting device is designed to

- at least one additive, in particular fibers, filaments, rovings, fabrics and/or nonwovens, to cut and/or

- to meter at least one cut additive, in particular fibers, filaments, rovings, fabrics and/or nonwovens, to the addition point and/or

- to produce at least one dimension of the at least one cut additive in a variably adjustable manner, in particular to cut fibers, filaments, rovings, fabrics and/or non-woven fabrics to variably adjustable lengths, and/or

- to cut with a rotating knife roller.

[0055] In the production of composite molded parts from at least one molding compound and at least one additive, it may be desirable to selectively reduce the additives to a specific size before adding them to the plasticizing stream. Since, for example, it is difficult to procure additives such as fibers with a specific dimension, especially a desired length, a comminution device for the individual selection of additive sizes, especially fiber lengths, can be particularly advantageous during dosing.

[0056] The size of the additives within a composite molded part, such as the fiber length in fiber composite molded parts, can have a significant influence on molded part properties such as strength, density or other molded part properties.

[0057] In a preferred embodiment, a glass fiber-reinforced composite molded part may require a specific length of glass fibers to achieve a certain strength. To accomplish this, the glass fibers can be cut before being added to the plasticizing stream. To add glass fibers of a specific length as an additive to a molding compound, a metering device can be used which, in addition to metering, also enables comminution, in particular cutting, of the additive. For this purpose, for example, a cutting unit for fibers, rovings, or the like can be used. Such a cutting unit could, for example, be a fiber chopper from the company Van der Mast.

[0058] The dosing device may additionally include a comminution device and/or simultaneously constitute a comminution device.

[0059] In a preferred embodiment, it can be provided that, with the aid of a suitable sensor, the lengths of the additives, in particular the fiber lengths, can be measured not only after the nozzle of the injection molding machine but instead and/or additionally within the injection molding machine, in particular within the forming tool.

[0060] According to a preferred embodiment of the injection molding machine, at least one degassing point is provided, wherein the degassing point

- in the first mass cylinder, preferably in the area before the transition of the first mass cylinder into the connecting line, and/or

- In the second mass cylinder, preferably in the flow direction of the plasticizing current in the area before and/or after the transition of the connecting line into the second mass cylinder and/or in the flow direction of the plasticizing current in the area of the end of the second mass cylinder, and/or

- in the connecting line between the at least two mass cylinders, preferably in the area before the transition of the connecting line into the second mass cylinder,

Ss Ss

Ss N

Sr 'hes AT 526 872 B1 2025-12-15

is arranged.

[0061] Depending on which materials are used for the molding process, it may be necessary to degas the plasticized molding compound and/or the additive. It may be advantageous to provide several degassing points and/or the possibility of degassing at various process-relevant points.

[0062] According to a preferred embodiment of the injection molding machine, it is provided that at least one filter is provided, preferably between the at least two melt cylinders.

[0063] Particularly for recycling applications, a filter may be provided. This filter may be located between the plasticizing screw and the injection screw and/or at another location within the injection molding machine. A filter can be operated continuously or discontinuously.

[0064] In a preferred embodiment, a combination of filters with degassing points and addition points may be particularly interesting for recycled PET (rPET).

[0065] According to a preferred embodiment of the injection molding machine, the drying device and/or the crystallizer is arranged upstream of the at least one hopper and/or the at least one first cylinder, wherein the drying device and/or the crystallizer arranged upstream of the at least one hopper and/or the at least one first cylinder is configured to dry the at least one molding compound and/or the at least one additive and to supply the at least one dried molding compound and/or the at least one dried additive to the at least one hopper and/or the at least one first cylinder, preferably wherein the at least one drying device and/or the at least one crystallizer has a stirring device.

[0066] Depending on the materials used for the forming process, it may be necessary to dry them before further processing. For example, when using crystalline PET, amorphous PET and/or heavily contaminated PET, a washing step followed by drying may be necessary.

[0067] In a preferred embodiment, at least one measuring device may be provided, wherein the at least one measuring device measures the temperature, pressure and/or viscosity of the plasticizing flow, preferably wherein the at least one measuring device is arranged between the at least two mass cylinders.

[0068] Particularly preferably, a rheometer can be provided to determine the quality of the material and to facilitate decision-making during the forming process. A rheometer can perform measurements inline and/or online.

[0069] Furthermore, protection is sought for a method for producing molded parts, in particular composite molded parts made of at least one molding compound and an additive, with an injection molding machine according to the invention, wherein the injection molding machine comprises:

- at least one first mass cylinder and one second mass cylinder,

- at least one connecting line between the at least two mass cylinders, wherein the connecting line directs the flow direction of the plasticizing current from the first mass cylinder to the second mass cylinder,

- at least one mass funnel for receiving at least one molding compound and/or at least one additive, wherein the at least one mass funnel is connected to the first mass cylinder, and

- at least one addition point for receiving at least one molding compound and/or at least one additive,

- at least one metering device is connected upstream of at least one mass hopper and/or at least one addition point, wherein the at least one metering device connected upstream of at least one mass hopper and/or at least one addition point supplies the at least one molding compound and/or the at least one additive to the at least one mass hopper and/or at least one addition point, and

- at least one drying device and/or at least one crystallizer is provided, and

- which provides at least one addition point for the at least one additive, wherein the at least one addition point is arranged in the second mass cylinder, preferably in the flow direction of the plasticizing stream in the area before and/or after the transition of the connecting line into the second mass cylinder and/or in the flow direction of the plasticizing stream in the area of the end of the second mass cylinder, and

- a mixing screw is provided, wherein the mixing screw is arranged in the second mass cylinder and

o has a mixing zone, wherein a mixer of the mixing zone is designed as a shearing element, as a maddock, as a shear-mixing element and/or as a toothed disc mixing element, and

- where an embossing tool is provided.

[0070] Further details and advantages of the invention are explained in more detail below with reference to the figures and the drawings. These show:

[0071] Fig. 1 Schematic of an injection molding machine for a single-stage process;

[0072] Fig. 2 and 3: different schematics of an injection molding machine for a 2-stage process;

[0073] Fig. 4 and 5: Schematics of an injection molding machine for a 2-stage process with a dosing device;

[0074] Fig. 6 to 8: Schematic diagrams of a single-stage compounding process and subsequent single-stage shaping process;

[0075] Fig. 9 to 16: different schematics of an injection molding machine for compounding and subsequent shaping in a 2-stage process.

[0076] Although various embodiments are presented below, these should not be considered limiting. The illustrated components, such as addition points, embossing tools, comminution devices, cutting devices, degassing points, filters, measuring devices, mixing screws and plugging screws, can be freely combined in number, position and design within an injection molding machine for a 2-stage process.

[0077] Like the components mentioned above, the metering device and the drying device and/or the crystallizer can also be freely configured within an injection molding machine for a 2-stage process. In contrast to the components mentioned above, their number is limited in that at least one metering device together with at least one drying device and/or at least one crystallizer is provided within an injection molding machine for a 2-stage process.

[0078] Fig. 1 shows a schematic of an injection molding machine 1 for a single-stage process.

[0079] Fig. 1 shows an injection molding machine consisting of a melt cylinder 2 and a molding tool 10. The melt cylinder 2 has an injection screw 13 and a melt hopper 6.

[0080] The molding compound 7 can be added to the mass cylinder 2 via the mass funnel 6-

It's AT 526 872 B1 2025-12-15

Ss N

The molding compound 7 is plasticized and homogenized by the influence of pressure and temperature and transported by the rotating injection screw 13 towards the molding tool 10.

[0081] Following the plasticization and homogenization of the molding compound 7, the molding compound 7 can be introduced into the molding tool, preferably injected.

[0082] The injection molding machine 1 and the associated forming tool 10 can be designed as a conventional injection molding machine with an injection mold. However, it is also conceivable that an injection compression molding machine with a compression mold is provided, in which the forming compound 7 is introduced, preferably injected, into the compression mold, which is not completely closed but sealed. Once the filling process is complete with the partial filling of the compression mold, the compression mold can be completely closed, with the complete closure corresponding to one compression stroke and thus representing the final forming.

[0083] For Fig. 1 as well as for all further figures, in addition to the already described embodiment variants of a conventional injection molding machine and an injection compression molding machine, other embodiments are also conceivable.

[0084] Figs. 2 and 3 show different schematics of an injection molding machine 1 for a 2-stage process.

[0085] The injection molding machine 1 in Fig. 2 comprises the first injection cylinder 2, the second injection cylinder 13, and the molding tool 10. The two injection cylinders 2 and 3 are connected to each other via a connecting line 4. The first injection cylinder 2 has a plasticizing screw 12. The second injection cylinder 3 includes an injection screw 13.

[0086] As shown in Fig. 2, the first mass cylinder 2 may be a plasticizing unit with at least one plasticizing screw 12 and/or the second mass cylinder 3 may be an injection unit with at least one injection screw 13.

[0087] A molding compound 7 can be added via the hopper 6, which is plasticized and homogenized by the two cylinders 2, 3. The molding compound 7 is conveyed by the two screws 12, 13 from the first cylinder 2 towards the second cylinder 3 and from the second cylinder towards the molding tool 10. Thus, the molding compound 7 flows from the hopper 6 in the flow direction 5 to the molding tool 10.

[0088] The injection molding machine 1 additionally has an opening that serves to degas the plasticized molding compound. This is therefore a degassing point 15.

[0089] This is an injection molding machine 1, in particular an injection molding machine, for producing molded parts, in particular composite molded parts, from at least one molding compound 7 and an additive 9, comprising:

- at least a first mass cylinder 2 and a second mass cylinder 3,

- at least one connecting line 4 between the at least two mass cylinders 2,3, wherein the connecting line 4 directs the flow direction 5 of the plasticizing current from the first mass cylinder 2 to the second mass cylinder 3,

- at least one mass funnel 6 for receiving molding compound 7, wherein the at least one mass funnel 6 is connected to the first mass cylinder 2,

- at least one addition point 8 for at least one additive 9 and

[0090] Fig. 3 shows an injection molding machine 1 for a 2-stage process, similar to the injection molding machine 1 from Fig. 2.

[0091] The statements made so far regarding Fig. 2 apply analogously to Fig. 3. For those embodiments that represent injection molding machines for 2-stage processes, the above can be assumed to apply mutatis mutandis, provided the same components are shown. For this reason, only differences are noted for the following figures.

It's AT 526 872 B1 2025-12-15

Ss N

[0092] In Fig. 3, the connecting line 4 does not go directly into the beginning of the mass cylinder 3, but opens into it in the flow direction 5 approximately after a quarter of the length of the mass cylinder 3.

[0093] In other words, the second mass cylinder 3 is extended at the point where the connecting line 4 is introduced into the mass cylinder 3, in the opposite direction to the flow 5 of the plasticizing stream. The degassing point 15 is located in this extension of the mass cylinder 3.

[0094] It should be noted here that the positions on the mass cylinders 2, 3, which represent a transition between the mass cylinders 2, 3 or between a mass cylinder and a connecting line 4, are not limited either specifically with regard to the embodiments disclosed herein or generally with regard to embodiments not disclosed herein. Such positions can be provided at any point on the existing mass cylinders.

[0095] Figs. 4 and 5 show schematic diagrams of an injection molding machine 1 for a 2-stage process with a dosing device.

[0096] As shown in Fig. 4, the second mass cylinder 3 can have an addition point 8. This can be designed as a funnel, similar to the mass funnel 6.

[0097] It can be provided that at least one metering device 23 is connected upstream of the at least one mass hopper 6 and/or the at least one addition point 8, as shown in Fig. 4, wherein the at least one metering device 23 connected upstream of the at least one mass hopper 6 and/or the at least one addition point 8 is designed to supply the at least one molding compound 7 and/or the at least one additive 9, as shown in Fig. 4, to the at least one mass hopper 6 and/or the at least one addition point 8.

[0098] As shown in Fig. 4, it can further be provided that the at least one metering device 23 is a comminution device 11, wherein the comminution device 11 is connected upstream of the at least one mass hopper 6 and/or the at least one addition point 8, wherein the comminution device 11 connected upstream of the at least one mass hopper 6 and/or the at least one addition point 8 is designed to comminute the at least one molding compound 7 and/or the at least one additive 9 and to supply the at least one comminution of the molding compound 7 and/or the at least one comminution of the additive 9 to the at least one mass hopper 6 and/or the at least one addition point 8.

[0099] As shown in Fig. 4, it can further be provided that the comminution device 11 is a cutting device, wherein the cutting device is designed to

- to cut and/or at least one additive 9, in particular fibers, filaments, rovings, fabrics and/or nonwovens

- to meter at least one cut additive 9, in particular fibers, filaments, rovings, fabrics and/or nonwovens, to the addition point 8 and/or

- to produce at least one dimension of the at least one cut additive 9 in a variably adjustable manner, in particular to cut fibers, filaments, rovings, fabrics and/or non-woven fabrics to variably adjustable lengths, and/or

to cut with a rotating knife roller 14.

[00100] The additive can be moved towards a knife roller 14 via circulating rollers 19. When the knife roller 14 comminutes, preferably cuts, the additive 9, the comminuted additive 9 can be metered piecewise into the dispensing point 8. As indicated in Fig. 4, the pieces of the comminuted additive 9 fall into the hopper of the dispensing point 8. The metering can be controlled by the conveying speed of the circulating rollers 19 in combination with the knife roller 14 and/or by the cutting process, in particular the size of the comminuted additive pieces 9. Timing and/or synchronization of the metered quantity of additive 9 with the quantity of plasticized molding compound 7 conveyed by the mass cylinders 2, 3 is also conceivable.

10 / 26

It's AT 526 872 B1 2025-12-15

Ss N

[00101] In a preferred embodiment, a forming tool 10 may be provided, preferably wherein the forming tool 10 is an embossing tool.

[00102] The injection molding machine 1 in Fig. 5 is very similar to the one in Fig. 4, wherein in Fig. 5 the metering device 23 is a screw feeder 25.

[00103] As shown in Fig. 5, it can be provided that the at least one metering device 23 is a plugging screw 25, wherein the plugging screw 25 is positioned upstream of the at least one mass hopper 6 and/or the at least one addition point 8, wherein the plugging screw 25 positioned upstream of the at least one mass hopper 6 and/or the at least one addition point 8 is designed to pre-extrude the at least one molding compound 7 and/or the at least one additive 9 and to supply the at least one pre-extruded molding compound 7 and/or the at least one pre-extruded additive 9 to the at least one mass hopper 6 and/or the at least one addition point 8.

[00104] A feed screw 25 is understood here to be an auxiliary unit which, for example in the form of an extruder, can feed molding compound 7 and/or an additive 9 to one of the mass cylinders in the 2-stage process. This can serve on the one hand for dosing and/or on the other hand to prevent material discharge from an opening, which is intended, for example, for ventilation or degassing.

[00105] Figures 6 to 8 show schematic diagrams of a single-stage compounding process and subsequent single-stage shaping process.

[00106] Fig. 6 shows a twin-screw extruder. An extruder for plasticizing and homogenizing a molding compound 7, possibly with an additive 9, can have only one screw, as shown in Fig. 7, or more than two screws.

[00107] The molding compound 7 can be added via the hopper 6 at one end of the twin-screw extruder 20. The molding compound 7 can then be extruded to the other end of the twin-screw extruder 20. As shown in Fig. 6, the additive 9 can be added via the feed port 8 approximately in the middle of the twin-screw extruder 20.

[00108] It should be noted here that the positions of the described components, such as metering devices, addition points, embossing tools, comminution devices, cutting devices, degassing points, filters, drying devices, crystallizers, measuring devices, mixing screws, and plugging screws, are not limited, either specifically with regard to the embodiments disclosed herein or generally with regard to embodiments not disclosed herein. The positions of the described components can be provided at any point on the existing mass cylinders and/or at any point on the existing connecting lines and/or in each of the existing mass cylinders and/or in each of the existing connecting lines.

[00109] During extrusion, the plasticizing stream can be conveyed to the comminution device 11. The comminution device 11 produces a cut molding compound 22 from the plasticized molding compound 7 and the additive 9, which can be collected in a container 21.

[00110] Fig. 7 shows another extruder 20 with a mass cylinder and, in contrast to Fig. 6, with only a single screw for plasticizing the molding compound 7 and the additive 9.

[00111] As shown in Fig. 7, the molding compound 7 and the additive 9 can be added to the extruder 20 via the mass hopper 6.

[00112] Before the plasticizing stream is further processed via a comminution device 11, as shown in Fig. 6, the plasticizing stream can flow through the filter 16 to separate impurities from the plasticized melt.

[00113] Fig. 8 shows an injection molding machine 1, comparable to that in Fig. 1, consisting of

It's AT 526 872 B1 2025-12-15

Ss N

a single mass cylinder 2 and a shaping tool 10.

[00114] The crushed molding compound 22, which can be obtained by an extruder 20 from Fig. 6 and/or 6, can be fed to the injection molding machine 1 as shown in Fig. 8.

[00115] A single-stage compounding process followed by single-stage molding has the disadvantage of placing considerable stress on the material. On the one hand, a comminution process is necessary to provide the molding compound 22, which consists of the initial molding compound 7 and the additive 9, and subsequent transport to the injection molding machine 1. On the other hand, the molding compound 7, 22 and the additive 9 must be heated and cooled twice, and repeated heating, plasticizing, and cooling can have a negative effect on the material properties.

[00116] Therefore, efficient and gentle compounding is advantageous, as it saves process steps and reduces material stress. This can be achieved through two-stage processes, where compounding and shaping are performed with a single machine. Suitable machines for this purpose are shown schematically in Figures 9 to 16.

[00117] Figures 9 to 16 show different schematics of an injection molding machine 1 for compounding and subsequent shaping in a 2-stage process.

[00118] What has been said so far about Figures 2 to 4 applies analogously to Figures 9 to 16. For this reason, only differences are mentioned for the following figures.

[00119] Figures 9 to 16 differ, among other things, in the positions of the addition points 8, at which one or more additives 9 are added to the molding compound 7, and/or in the positions and/or number of the degassing points 15, at which the molding compound 7, possibly with an additive 9, can be degassed.

[00120] It should be noted that in preferred embodiments, the at least one addition point 8 may be provided for the at least one additive 9, preferably for fibers, powder and/or granules, particularly preferably for long glass fiber granules (LGF granules), wherein the addition point 8

- in the first mass cylinder 2, preferably in the area before the transition of the first mass cylinder 2 into the connecting line 4, and/or

- In the second mass cylinder 3, preferably in the flow direction 5 of the plasticizing stream in the area before and/or after the transition of the connecting line 4 into the second mass cylinder 3 and/or in the flow direction 5 of the plasticizing stream in the area of the end of the second mass cylinder 3, and/or

- in the connecting line 4 between the at least two mass cylinders 2,3, preferably in the area before the transition of the connecting line 4 into the second mass cylinder 3,

is arranged.

[00121] It should be noted that in preferred embodiments, at least one degassing point 15 may be provided, wherein the degassing point 15

- in the first mass cylinder 2, preferably in the area before the transition of the first mass cylinder 2 into the connecting line 4, and/or

- In the second mass cylinder 3, preferably in the flow direction 5 of the plasticizing stream in the area before and/or after the transition of the connecting line 4 into the second mass cylinder 3 and/or in the flow direction 5 of the plasticizing stream in the area of the end of the second mass cylinder 3, and/or

- in the connecting line 4 between the at least two mass cylinders 2,3, preferably in the area before the transition of the connecting line 4 into the second mass cylinder-

Ss N

linder 3, arranged.

[00122] It should be noted that the number and embodiments of the mass funnels, addition points and/or degassing points in Figs. 9 to 16 are not limited to the illustrated embodiments.

[00123] The metering devices 23 in Figures 9 to 16 can be designed as extruders. However, they can also have any other shape, depending on the type and quantity of the desired additive 9.

[00124] The metering devices 23 in Figs. 9 to 16 can have a comminution device 11, similar to the embodiment in Fig. 4.

[00125] As shown in Figs. 11, 12 and 14 to 16, it can be provided that at least one filter 16 is provided, preferably between the at least two mass cylinders 2,3.

[00126] As shown in Figures 14 to 16, it can be provided that at least one measuring device 18 is provided, wherein the at least one measuring device 18 measures the temperature, pressure and/or viscosity of the plasticizing flow, preferably wherein the at least one measuring device 18 is arranged between the at least two mass cylinders 2,3.

[00127] As shown in Figures 13 and 14, a mixing screw 26 can be provided in the second mass cylinder 3. The mixing screw 26 can perform the functions of a plasticizing screw 12 and/or an injection screw 13.

[00128] The mixing screw 26 has a mixing zone 24. The mixing screw 26 and/or the mixing zone 24 can be designed differently, for example as a shearing section, maddock, shear-mixing section or toothed disc mixing section.

[00129] A mixing zone is that area of the screw in which special mixing elements are provided on the screw, thereby increasing the mixing performance. This is particularly important for homogeneous mixing of additives. There can be more than one mixing zone along a screw.

[00130] As shown in Fig. 16, it can be provided that at least one drying device 17 and/or at least one crystallizer 17 is provided, wherein the drying device 17 and/or the crystallizer 17 is connected upstream of the at least one mass hopper 6 and/or the at least one first mass cylinder 2, wherein the drying device 17 and/or the crystallizer 17 connected upstream of the at least one mass hopper 6 and/or the at least one first mass cylinder 2 is configured to dry the at least one molding compound 7 and/or the at least one additive 9 and to supply the at least one dried molding compound 7 and/or the at least one dried additive 9 to the at least one mass hopper 6 and/or the at least one first mass cylinder 2, preferably wherein the at least one drying device 17 and/or the at least one crystallizer 17 has a stirring device.

[00131] A drying device 17 and/or a crystallizer 17, preferably with a stirring device, is particularly advantageous when the molding compound 7 is to be washed and/or dried before plasticizing.

[00132] If, for example, a recycled material is to be used as a molding compound 7, this recycled material is generally provided in sorted form before plasticizing and washed before reprocessing. Subsequently, the clean recycled material can be placed in a drying device 17 and/or a crystallizer 17. The drying device 17 and/or the crystallizer 17 dries the recycled material, and, as shown in Fig. 16, it can then be fed directly to the first batch cylinder 2.

[00133] A recycled material is a material that is reused. For example, molded parts are manufactured from virgin PET (polyethylene terephthalate). It is also now commonly used in-

It's AT 526 872 B1 2025-12-15

8 N 8

It is possible to mix recycled PET (rPET) with virgin PET for the production of molded parts in order to save on material costs and produce more sustainably. The base molding compound 7 can be exclusively virgin PET, exclusively recycled PET, or a mixture of virgin PET and rPET. The additive can be virgin PET, recycled PET, a mixture of virgin PET and rPET, and/or another additive.

14 / 26

It's AT 526 872 B1 2025-12-15

REFERENCE MARK LIST:

1 injection molding machine

2 first mass cylinder

3 second mass cylinder

4 connecting cable

5 Direction of plasticizing current flow 6 Mass funnel

7 Molding compound

8th encore

9 Additive

10 shaping tools

11. Shredding device

12 plasticizing screws

13 Injection screw

14 knife roller

15 Degassing point

16 filters

17 Drying device and/or crystallizer 18 Measuring device

19 Circulation roller

20 twin-screw extruders

21 collection containers

22 Composite material made of molding compound and additive 23 Dosing device

24 Mixed Zone

25 stuffing snail

26 Mixing auger

Claims (1)

It's AT 526 872 B1 2025-12-15 Ss N Patent claims 1. Injection molding machine (1) for producing molded parts, in particular composite molded parts made of at least one molding compound (7) and an additive (9), comprising: - at least a first mass cylinder (2) and a second mass cylinder (3), - at least one connecting line (4) between the at least two mass cylinders, wherein the connecting line (4) directs the flow direction (5) of the plasticizing current from the first mass cylinder (2) to the second mass cylinder (3), - at least one mass funnel (6) for receiving at least one molding compound (7) and/or at least one additive, wherein the at least one mass funnel (6) is connected to the first mass cylinder (2), and - at least one addition point (8) for receiving at least one molding compound and/or at least one additive (9), where - at least one metering device is connected upstream of the at least one mass hopper (6) and/or the at least one addition point (8), wherein the at least one metering device connected upstream of the at least one mass hopper (6) and/or the at least one addition point (8) is designed to supply the at least one molding compound (7) and/or the at least one additive (9) to the at least one mass hopper (6) and/or the at least one addition point (8), and - at least one drying device (17) and/or at least one crystallizer (17) is provided, characterized by the fact that - the at least one addition point (8) for the at least one additive (9) is provided, wherein the at least one addition point (8) is arranged in the second mass cylinder (3), preferably in the flow direction (5) of the plasticizing stream in the area before and/or after the transition of the connecting line (4) into the second mass cylinder (3) and/or in the flow direction (5) of the plasticizing stream in the area of the end of the second mass cylinder (3), and - a mixing screw (26) is provided, wherein the mixing screw (26) o is arranged in the second mass cylinder (3) and o has a mixing zone (24), wherein a mixer of the mixing zone (24) is configured as a shearing element, as a maddock, as a shear-mixing element and/or as a toothed disc mixing element, and - a stamping tool is provided. 2. Injection molding machine (1) according to claim 1, characterized in that the first melt cylinder (2) is a plasticizing unit with at least one plasticizing screw (12) and/or the second melt cylinder (3) is an injection unit with at least one injection screw (13). 3. Injection molding machine (1) according to claim 1 or 2, characterized in that the at least one addition point (8) is provided for the at least one additive (9), preferably for fibers, powder and/or granules, particularly preferably for long glass fiber granules (LGF granules), wherein the addition point (8) - in the first mass cylinder (2), preferably in the area before the transition of the first mass cylinder (2) into the connecting line (4), and/or - is arranged in the connecting line (4) between the at least two mass cylinders, preferably in the area before the transition of the connecting line (4) into the second mass cylinder (3). 4. Injection molding machine (1) according to one of claims 1 to 3, characterized in that a mixing screw (26) is provided, wherein the mixing screw (26) is a plasticizing screw (12) or an injection screw (13). 5. Injection molding machine (1) according to one of claims 1 to 4, characterized in that the at least one metering device is a comminution device (11), wherein the comminution- 16 / 26 10. AT 526 872 B1 2025-12-15 The comminution device (11) is connected upstream of the at least one mass hopper (6) and/or the at least one addition point (8), wherein the comminution device (11) connected upstream of the at least one mass hopper (6) and/or the at least one addition point (8) is designed to comminute the at least one molding compound (7) and/or the at least one additive (9) and to feed the at least one comminution of the molding compound (7) and/or the at least one comminution of the additive (9) to the at least one mass hopper (6) and/or the at least one addition point (8). Injection molding machine (1) according to claim 5, characterized in that the crushing- rung device (11) is a cutting device, wherein the cutting device is designed to- is educated - to cut and/or at least one additive (9), in particular fibers, filaments, rovings, fabrics and/or nonwovens - to meter at least one cut additive (9), in particular fibers, filaments, rovings, fabrics and/or nonwovens, to the addition point (8) and/or - to produce at least one dimension of the at least one cut additive (9) in a variably adjustable manner, in particular to cut fibers, filaments, rovings, fabrics and/or nonwovens to variably adjustable lengths, and/or - to cut with a rotating knife roller (14). Injection molding machine (1) according to one of claims 1 to 6, characterized in that at least one degassing point (15) is provided, wherein the degassing point (15) - in the first mass cylinder (2), preferably in the area before the transition of the first mass cylinder (2) into the connecting line (4), and/or - In the second mass cylinder (3), preferably in the flow direction (5) of the plasticizing current in the area before and/or after the transition of the connecting line (4) into the second mass cylinder (3) and/or in the flow direction (5) of the plasticizing current in the area of the end of the second mass cylinder (3), and/or - In the connecting line (4) between the at least two mass cylinders, preferably in the area before the transition of the connecting line (4) into the second mass cylinder (3), is arranged. Injection molding machine (1) according to one of claims 1 to 7, characterized in that at least one filter (16) is provided, preferably between the at least two melt cylinders. Injection molding machine (1) according to one of claims 1 to 8, characterized in that the drying device (17) and/or the crystallizer (17) is connected upstream of the at least one hopper (6) and/or the at least one first cylinder (2), wherein the drying device (17) connected upstream of the at least one hopper (6) and/or the at least one first cylinder (2) and/or the crystallizer (17) connected upstream of the at least one hopper (6) and/or the at least one first cylinder (2) is configured to dry the at least one molding compound (7) and/or the at least one additive (9) and to supply the at least one dried molding compound (7) and/or the at least one dried additive (9) to the at least one hopper (6) and/or the at least one first cylinder (2), preferably wherein the at least one drying device (17) and/or the at least one crystallizer (17) has a stirring device. Methods for manufacturing molded parts, in particular composite molded parts made of at least a molding compound (7) and an additive (9), with an injection molding machine (1) wherein the Injection molding machine (1) has: - at least a first mass cylinder (2) and a second mass cylinder (3), - at least one connecting line (4) between the at least two mass cylinders, wherein the connecting line (4) directs the flow direction (5) of the plasticizing current from the first mass cylinder (2) to the second mass cylinder (3), Ss N - at least one mass funnel (6) for receiving at least one molding compound (7) and/or at least one additive, wherein the at least one mass funnel (6) is connected to the first mass cylinder (2), and - at least one addition point (8) for receiving at least one molding compound and/or at least one additive (9), where - at least one metering device is connected upstream of the at least one mass hopper (6) and/or the at least one addition point (8), wherein the at least one metering device connected upstream of the at least one mass hopper (6) and/or the at least one addition point (8) supplies the at least one molding compound (7) and/or the at least one additive (9) to the at least one mass hopper (6) and/or the at least one addition point (8), and - at least one drying device (17) and/or at least one crystallizer (17) is provided, and - the at least one addition point (8) for the at least one additive (9) is provided, wherein the at least one addition point (8) is arranged in the second mass cylinder (3), preferably in the flow direction (5) of the plasticizing stream in the area before and/or after the transition of the connecting line (4) into the second mass cylinder (3) and/or in the flow direction (5) of the plasticizing stream in the area of the end of the second mass cylinder (3), and - a mixing screw (26) is provided, wherein the mixing screw (26) o is arranged in the second mass cylinder (3) and o has a mixing zone (24), wherein a mixer of the mixing zone (24) is configured as a shearing element, as a maddock, as a shear-mixing element and/or as a toothed disc mixing element, and - a stamping tool is provided. This includes 8 sheets of drawings. 18 / 26