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EP3036274A1 - Procédé de fabrication d'un composant en matériau polymère - Google Patents

Procédé de fabrication d'un composant en matériau polymère

Info

Publication number
EP3036274A1
EP3036274A1 EP14758512.9A EP14758512A EP3036274A1 EP 3036274 A1 EP3036274 A1 EP 3036274A1 EP 14758512 A EP14758512 A EP 14758512A EP 3036274 A1 EP3036274 A1 EP 3036274A1
Authority
EP
European Patent Office
Prior art keywords
fiber structure
polymer
semifinished product
component
injection mold
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP14758512.9A
Other languages
German (de)
English (en)
Inventor
Andreas Radtke
Oliver Geiger
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BASF SE
Original Assignee
BASF SE
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by BASF SE filed Critical BASF SE
Priority to EP14758512.9A priority Critical patent/EP3036274A1/fr
Publication of EP3036274A1 publication Critical patent/EP3036274A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14631—Coating reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles

Definitions

  • the invention is based on a method for producing a component from a polymer material by an injection molding method, comprising the following steps:
  • fiber reinforced polymer components are used in areas where materials of high strength and lower weight than metals are to be used.
  • components made of fiber-reinforced polymers are used in the automotive industry to reduce the mass of vehicles and thus the Kraftstoffverbrach.
  • thermoset materials so-called orga- nobleche, ie fully consolidated continuous fiber-reinforced thermoplastic polymers with fabric or scrim reinforcement, are being used more and more recently.
  • orga- nobleche ie fully consolidated continuous fiber-reinforced thermoplastic polymers with fabric or scrim reinforcement.
  • These organic sheets can be injected by injection molding with polymers, if the organic sheets are thin enough or are heated above the melting temperature.
  • the object of the present invention is to provide a method for the production of fiber-reinforced components with which components with a small wall thickness can also be produced by overmolding or overmolding a fiber structure or a fiber structure containing a hemisphere, wherein the wall thickness is less than in the methods known from the prior art.
  • the object is achieved by a method for producing a component from a polymer material by an injection molding method, which comprises the following steps:
  • flow channels for the polymer in the tool in areas where the fiber structure or the semifinished product containing the fiber structure lies and the polymer thus flows over the fiber structure or the semifinished product containing the fiber structure have a height with which wall thicknesses in the range of 0, 5 to 2.5 mm, preferably in the range of 1 to 2 mm.
  • fiber structure is understood as meaning a woven fabric, a knitted fabric, a scrim, a unidirectional or bidirectional fiber structure made of continuous fibers or disordered fibers, the fiber structure being impregnated with a polymer.
  • the fiber structure is a scrim
  • individual fibers may be arranged in multiple layers of parallel fibers, wherein the individual layers may have a direction rotated towards one another. It is particularly preferred if the fibers of the individual layers are rotated at an angle of 30 ° -90 ° to each other.
  • an increase in the tensile strength of the molding in several directions is achieved. In a unidirectional orientation, an increase in the tensile strength is achieved in particular in the direction of the fiber orientation.
  • An increase in the compressive strength of the component from the molded part is also achieved transversely to the orientation of the fibers.
  • the fiber structure comprises a woven or knitted fabric, it is possible to provide multiple layers or only one layer of fibers.
  • multiple layers mean that multiple fabrics are to be stacked. The same applies to an arrangement of the fiber structure as a knitted fabric.
  • Suitable fibers that can be used to increase the stability of the components are, in particular, carbon fibers, glass fibers, aramid fibers, metal fibers, polymer fibers, potash and titanate fibers, boron fibers, basalt fibers or other mineral fibers. It is particularly preferred if at least some of the fibers used are metal fibers. Particularly suitable as metal fibers are fibers based on iron-containing metals, in particular based on steel.
  • the fibrous structure includes steel cords, steel wires or steel fibers.
  • the fiber structure may contain exclusively steel cords, steel wires or steel fibers. or a mixture of steel cords, steel wires or steel fibers and of non-metallic fibers, particularly preferably carbon fibers or glass fibers.
  • steel cords, steel wires or steel fibers has the advantage that in particular a high tensile strength of the molded parts thus produced is achieved.
  • a significant advantage of using steel cords is ensuring component integrity in crash or impact loading where a glass or carbon fiber reinforced structure would lose its integrity.
  • a mixture of metal fibers and carbon fibers or glass fibers for reinforcement it is possible, for example, to interweave individual steel cords, steel wires or steel fibers with carbon fibers or glass fibers.
  • different fibers can be inserted in the form of a jelly in the tool. In this case, the fibers can be inserted either alternately or in any statistically distributed order. It is also possible, for example, to introduce fibers from one material in one direction and fibers from another material in a direction rotated to this direction.
  • steel cords steel wires or steel fibers
  • they are interwoven with glass fibers or carbon fibers to obtain a fabric.
  • a uniform reinforcement of the molded part can then be achieved, for example, by arranging the individual fabrics twisted in multiple layers.
  • two layers that are rotated by 90 ° to each other can be used.
  • any other angle is possible.
  • more than two layers can be used.
  • the use of metal fibers, for example in the form of steel cords, steel wires or steel fibers together with fibers of another material, for example carbon fibers or glass fibers, allows molded parts to be produced with improved failure behavior.
  • a semifinished product it is possible, for example, to impregnate the fiber structure with a polymer material, in particular a thermoplastic polymer.
  • a polymer material in particular a thermoplastic polymer.
  • polymer precursor compounds for example monomers
  • the fiber structure is impregnated with a polymer precursor compound and subsequently the fiber structure so impregnated is encapsulated with a further polymer precursor compound
  • the polymer used to produce the semifinished product is the same as the polymer used for encapsulation or overspotting.
  • the use of different polymers is particularly advantageous if certain properties, for example with regard to surface quality or strength, are to be achieved by overmoulding or overspotting.
  • thermoplastic polymers are, for example, polymethyl methacrylate, polybutylene terephthalate, polyethylene terephthalate, polycarbonate, polyether ether ketone, polyether ketone, polyethersulfone, polyphenylene sulfide, polyethylene naphthalate, polybutylene naphthalate, polyamide, polypropylene, polyethylene or mixtures of at least two of these polymers.
  • a semifinished product containing a fibrous structure is used to produce the component, it is possible to use a semifinished product in which the fiber structure is impregnated with a polymer, the polymer being completely polymerized. Alternatively, it is also possible to use a semifinished product which has been impregnated with a polymer precursor compound and the polymer precursor compound has solidified but not yet fully polymerized. In this case, the precursor compound polymerizes, for example, in the mold.
  • the semifinished product containing the fibrous structure is in particular a fabric in which the fabric structure is impregnated with the polymer or a polymer precursor compound.
  • a sheet is, for example, an organic sheet or a thermoplastic laminate.
  • functional parts are produced on the component with the encapsulation or overmolding in step (b).
  • Such functional elements are for example ribs, as they are usually formed to reinforce a component of a polymer material.
  • the functional elements can also be, for example, fixtures for fastening elements, clips, force injections, screw-on domes, threaded receptacles or any other functional elements which can be produced by injection molding from the polymer material.
  • the injected polymer between the functional elements forms a closed skin on the fiber structure or the semifinished product containing the fiber structure.
  • an additional stabilization of the functional elements is achieved by the closed skin between the functional elements.
  • the closed skin is thereby formed by forming a thin flow channel between the functional elements and injecting the polymer material into the flow channel.
  • the formation of the skin on the fiber structure or the semifinished product containing the fiber structure additionally produces an improved connection of the polymer material for the functional element with the fiber structure or the semifinished product containing the fiber structure.
  • the primer can serve, for example, as a bonding agent between the fiber structure and polymers.
  • a soluble polyamide is suitable. This is applied in the form of a solution and then the solvent is removed.
  • a soluble polyamide is particularly suitable if a component made of a fiber-reinforced polyamide is to be produced by the method according to the invention.
  • the semifinished product containing the fibrous structure is preheated.
  • Preheating softens the polymer material of the semifinished product and the injected thermoplastic polymer can weld to the polymer material of the semifinished product and in this way form a dimensionally stable connection.
  • the preheating of the semifinished product further allows the semifinished product to be formed before or during insertion into the injection mold.
  • the forming of the semifinished product is required, for example, in order to adapt a flat semifinished product to the component shape to be produced.
  • the preheating of the semifinished product containing the fibrous structure can be carried out, for example, in the injection mold for producing the encapsulation or overmolding.
  • the semifinished product containing the fibrous structure is inserted into the injection mold and the injection mold is heated, so that the inserted semifinished product containing the fibrous structure is also leveled. if heated.
  • the heating can be carried out in any manner known to those skilled in the art.
  • any device known to those skilled in the art can be used with which the semifinished product containing the fiber structure can be heated.
  • it is possible, for example, to electrically heat the tool containing the fiber structure to heat it by heat radiation, to heat it by microwave radiation or to hang it up on a heated plate for heating.
  • the temperature to which the semifinished product containing the fibrous structure is heated is preferably chosen such that the polymer of the semifinished product softens. In this case, furthermore, the temperature is preferably selected so that the polymer does not melt completely, so that no polymer can run out of the semifinished product and in this way the semifinished product is damaged.
  • additives can be added.
  • Commonly used additives are, for example, hardeners, crosslinkers, plasticizers, catalysts, toughening agents, adhesion promoters, fillers, mold release agents, blends with other polymers, stabilizers or mixtures of two or more of these components.
  • Additives or optionally also comonomers which can be used to adjust the properties of the polymer are known to the person skilled in the art.
  • the component produced by the method according to the invention is particularly advantageously a structural component, a bulkhead, a floor assembly, a battery carrier, a side impact carrier, a bumper system, a structural insert or a pillar reinforcement in a motor vehicle.
  • the component can, for example, also be a side wall, a structural fender, a side member or any other component of a vehicle body.
  • the component according to the invention may also be a housing of a rock mill, a protective cage or a housing for a lathe or pressing machine, or a support structure.
  • the method according to the invention makes it possible to produce components with more robust structures than has hitherto been possible from the prior art.
  • the method according to the invention is also particularly suitable for providing the component with a so-called in-mold coating.
  • the surface coating of the component is generated directly in the injection mold.
  • conventional coating method is thereby a good adhesion of the coating material obtained on the molding and thus achieved a particularly high quality coating.
  • thermoplastic polymer in step (b) takes place according to the invention under the usual parameters for injection molding.
  • the use of the polymer-soaked fiber structure has a positive effect on the run length of the polymer in the flow channels. It can be sprayed with a few sprues larger areas than would be expected.
  • the polymer is injected at a lower pressure than would have been expected on the basis of the methods known from the prior art. Even with a lower injection pressure, a complete, defect-free filling of the mold can be achieved if, according to the invention, a semi-finished product containing a fibrous structure or a polymer-impregnated fibrous structure is inserted.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Materials Engineering (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un composant en matériau polymère par une technique de moulage par injection, ledit procédé comprenant les étapes consistant à : (a) introduire un demi-produit contenant une structure fibreuse ou introduire une structure fibreuse imprégnée de polymère dans un outil de moulage par injection, (b) injecter un polymère thermoplastique en fusion dans l'outil de moulage par injection de façon à enrober ou surmouler le demi-produit contenant la structure fibreuse ou la structure fibreuse, (c) laisser le polymère solidifier et retirer le composant de l'outil de moulage par injection. Les canaux d'écoulement du polymère en fusion qui entourent la structure fibreuse ou le demi-produit contenant la structure fibreuse sont dimensionnés de telle façon que l'épaisseur de paroi du composant fini correspond à l'épaisseur de paroi qui peut être obtenue pour un composant sans structure fibreuse incorporée.
EP14758512.9A 2013-08-19 2014-08-15 Procédé de fabrication d'un composant en matériau polymère Withdrawn EP3036274A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP14758512.9A EP3036274A1 (fr) 2013-08-19 2014-08-15 Procédé de fabrication d'un composant en matériau polymère

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP13180883 2013-08-19
EP14758512.9A EP3036274A1 (fr) 2013-08-19 2014-08-15 Procédé de fabrication d'un composant en matériau polymère
PCT/EP2014/067495 WO2015024879A1 (fr) 2013-08-19 2014-08-15 Procédé de fabrication d'un composant en matériau polymère

Publications (1)

Publication Number Publication Date
EP3036274A1 true EP3036274A1 (fr) 2016-06-29

Family

ID=48985683

Family Applications (1)

Application Number Title Priority Date Filing Date
EP14758512.9A Withdrawn EP3036274A1 (fr) 2013-08-19 2014-08-15 Procédé de fabrication d'un composant en matériau polymère

Country Status (6)

Country Link
US (1) US20160207237A1 (fr)
EP (1) EP3036274A1 (fr)
JP (1) JP2016531777A (fr)
KR (1) KR20160045123A (fr)
CN (1) CN105637017A (fr)
WO (1) WO2015024879A1 (fr)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10583595B2 (en) 2013-08-21 2020-03-10 Basf Se Method for producing a composite plastic part (CK)
EP3036275B1 (fr) 2013-08-21 2018-03-07 Basf Se Pièce de matière plastique composite avec une adhésion améliorée entre les composants de matière plastique contenus
US9945163B2 (en) * 2015-05-28 2018-04-17 Fca Us Llc Vehicle door handle apparatus and two-shot injection molding process for producing components with a metallic surface finish
US20200331246A1 (en) * 2019-04-17 2020-10-22 Columbia Insurance Company Cross-ply backing materials and carpet compositions comprising same

Family Cites Families (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2503782B2 (ja) * 1990-12-21 1996-06-05 住友化学工業株式会社 多層成形品の成形方法
DE10107269A1 (de) * 2001-02-16 2002-08-22 Volkswagen Ag Verfahren zur Herstellung eines Innenverkleidungsteiles
DE10207080A1 (de) * 2002-02-20 2003-08-28 Krauss Maffei Kunststofftech Verfahren und Vorrichtung zum Herstellen von Kunststoffformteilen
DE102005057181A1 (de) * 2005-11-29 2007-06-06 Lanxess Deutschland Gmbh Verbinden von faserverstärktem Material mit einem Spritzgussmaterial
DE102006040748A1 (de) * 2006-08-31 2008-03-06 Daimler Ag Spritzgussverfahren für faserverstärkte Kraftfahrzeugteile
TW201023715A (en) * 2008-12-04 2010-06-16 Pegatron Corp Fiber-reinforced polymeric casing and method of fabricating the same
DE102009056124B4 (de) * 2009-05-04 2021-12-16 Oechsler Ag Tiefgezogenes Kunststoff-Umformteil
DE102009034767A1 (de) * 2009-07-25 2011-01-27 Lanxess Deutschland Gmbh & Co. Kg Organoblechstrukturbauteil
DE102011012143B4 (de) * 2011-02-24 2015-11-05 Daimler Ag Faserkunststofflaminat-Bauteil
DE102011005350A1 (de) * 2011-03-10 2012-09-13 Lisa Dräxlmaier GmbH Verfahren und Vorrichtung zur Herstellung eines Formteils mit faserverstärktem Träger und Funktionsteilen
US20130221555A1 (en) * 2011-08-26 2013-08-29 Basf Se Process for producing moldings

Non-Patent Citations (1)

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Title
See references of WO2015024879A1 *

Also Published As

Publication number Publication date
WO2015024879A1 (fr) 2015-02-26
JP2016531777A (ja) 2016-10-13
KR20160045123A (ko) 2016-04-26
US20160207237A1 (en) 2016-07-21
CN105637017A (zh) 2016-06-01

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