EP2305869B1 - Dispositif et procédé de fabrication de pièces de formage à partir de matériaux en fibres - Google Patents

Dispositif et procédé de fabrication de pièces de formage à partir de matériaux en fibres Download PDF

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Publication number
EP2305869B1
EP2305869B1 EP10010798.6A EP10010798A EP2305869B1 EP 2305869 B1 EP2305869 B1 EP 2305869B1 EP 10010798 A EP10010798 A EP 10010798A EP 2305869 B1 EP2305869 B1 EP 2305869B1
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EP
European Patent Office
Prior art keywords
fibers
mold
mould
fibres
nozzle
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Active
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EP10010798.6A
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German (de)
English (en)
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EP2305869A1 (fr
Inventor
Egon FÖRSTER
Manfred Heinl
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Robert Buerkle GmbH
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Robert Buerkle GmbH
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Publication of EP2305869A1 publication Critical patent/EP2305869A1/fr
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/736—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged characterised by the apparatus for arranging fibres

Definitions

  • the invention relates to a device for producing three-dimensional molded parts made of fiber material, in particular according to the preamble of patent claim 1.
  • Such moldings are preferably used in vehicle construction, in particular as a sound insulation mat, such as under the hood, as a lining mat in the footwell or in the trunk or in the seat upholstery or floor carpets, etc.
  • Such a device is for example from the WO 2009/062646 has become known and discloses an apparatus for producing three-dimensional molded parts made of fiber material.
  • a two-part form consisting of upper and lower mold is used.
  • the respective inner sides of the upper and lower molds partially determine the contour of the molded part.
  • fibers are injected by an air flow through several nozzles.
  • the air flow escapes through openings in the upper and lower molds so that the fibers attach to the insides of the upper and lower molds.
  • the fibers are optionally still locally compacted, and then to glue together in another step by supplying heat. After cooling of the fibers then finally the finished molded part can be removed from the mold.
  • the fibers form in the form of a so-called random fiber fleece, that is, the fibers of the fleece are arranged arbitrarily with respect to their respective orientation.
  • the invention is based on the recognition that such molded parts should be better adapted to the later applications with regard to product-specific properties.
  • the object of the present invention is therefore to provide a method and an apparatus for producing three-dimensional molded parts made of fiber material, in order to improve the possible uses and properties of molded parts.
  • the object is achieved in a device according to the preamble of claim 1 by its characterizing features.
  • the fibers in the interior of the mold align themselves better in accordance with the electric field or along the respective field lines of the electric fields. Subsequently, the fibers then deposit in a preselectable preferred direction on the inside of the mold. If the mold is completely filled with fibers oriented in this way, the fibers are glued together and retain the orientation of the respective electric field during bonding. This results in a molded part whose fibers are aligned in certain areas or in the entire molded part.
  • the directions of the electric fields or the field lines are chosen so that the respective directions of the fibers coincide with one or more preferred directions for certain properties.
  • the pre-alignment of the fibers causing conveying element is designed as a cylinder.
  • the fibers are provided with an electrical charge before and / or during the blowing in and / or the charging of already charged fibers is intensified.
  • the fibers then align with the one or more electric fields to form a molded article having one or more desired fiber preferred directions.
  • already charged fibers their charge can be increased so that they align faster and more reliable according to the field lines of the electric fields in the interior and finally aligned in the manufactured molded part.
  • the conductive sections of the mold are arranged so that the directions of the electric fields or the field lines correspond to the desired preferred directions of the fibers. Conductive portions of the mold can each be isolated from each other. As a result, additional means for generating the electric fields are unnecessary and the process can be carried out more cheaply.
  • the at least one electric field can also be generated by electrodes which are arranged offset on the outer sides of the multi-part mold or outwardly. This ensures easy accessibility of the electrodes and maintenance of the electrodes.
  • the electrodes In addition, in the positioning of the electrodes less boundary conditions, for example. Projections, etc., to pay attention, so that the electrodes can be made larger, which favors the homogeneity of the field between the respective electrodes, because edge effects of the fields at the respective edges of the electrodes play a minor role.
  • the blowing of fiber material into the interior takes place by at least one nozzle, which is itself formed as an electrode for at least one electric field.
  • the nozzle may consist of sections isolated from one another, in order to produce individual partial fields in different directions.
  • a plurality of nozzles may be formed as an electrode.
  • the corresponding corresponding second electrode for the electric field need not necessarily also be present in the form of a nozzle, but may for example also have any other expedient shape, in particular, this can also be formed by conductive portions of the mold, which are optionally electrically isolated from each other.
  • the means for electrical charging are arranged on the at least one nozzle and / or on one of the nozzle supply lines. If the charging means are arranged on the nozzle, a compact construction of the device is thus achieved. If the means are arranged on a supply line for at least one nozzle, the fibers are given the desired charge even before they are blown into the interior space. In this way, the nozzle can be produced relatively simply and inexpensively, at the same time influencing the electric fields in the interior of the Form by the means for electrical charging, if they are arranged on the nozzle itself, avoided and thus achieves a reliable alignment of the fibers in the interior by the one or the electric fields.
  • the means for electrically charging the fibers comprise a ring electrode.
  • the means can be particularly easily integrated into existing feed lines for the nozzles or in the nozzles themselves, for example by the annular electrode is formed directly as a portion of the feed line or simply arranged around the feed line on the outside thereof.
  • the two types of electrodes can also be used together for the generation of an electric field, for example by a stick electrode being arranged on one side of the mold and a plate-shaped electrode on the opposite side.
  • the field lines are perpendicular to the rod-shaped electrode to the surface thereof and terminate in parallel on the surface of the plate-shaped electrode.
  • the device can be made as compact as possible, it is expedient that at least part of the multi-part mold is at least partially formed as an electrode.
  • This "embedding" of the electrode in the mold allows for a more compact design of the form, on the other hand, the fields are largely homogeneous, because no disturbing additional leads in the field of electric fields must be arranged, which would disturb the homogeneity of the electric fields.
  • the multi-part mold is made partly of non-conductive material. If the electrodes are arranged on the outside, they are easily accessible from the outside.
  • the multi-part mold is partially made of non-conductive material in order to avoid partial shielding of the electric fields by the Faraday effect. It can also serve a corresponding design of the form by means of conductive and non-conductive materials that the Faraday effect is exploited to selectively influence the or the electric fields in the field strength and geometric orientation.
  • the electrodes When the electrodes are arranged on the outer sides of the multi-part mold, it is not necessary that they are connected to the multi-part mold. For example, by positioning electrodes farther away from the multi-part mold, they can be made much larger than the mold or at least portions of the mold. At the same time, this also avoids edge effects in the electric field (bulges of the field lines at the edge of the electrode, plate-shaped electrodes directly opposite have only a homogeneous field substantially in the interior space between the plates).
  • both a nozzle with a differently shaped electrode can form means for generating electric fields and two corresponding nozzles.
  • FIG. 1 is a multi-part mold 1 shown for a device according to the invention.
  • the mold 1 consists of two perforated, shell-like parts, upper mold O and lower mold U, which form between them an interior I, which has the shape of the molded part to be produced.
  • two plate-shaped electrodes 2a, 2b are arranged, which serve to generate an electric field E, which acts in the inner space I.
  • On the right side of the lower mold U in FIG. 1 is a nozzle D arranged for blowing fibers F 1 , F 2 in the interior I.
  • an electrode 2c attached to the nozzle D in the interior I, which for static charging of the fibers F 1 , F 2 during their injection into the interior I serves.
  • the interior is acted upon before, but at the latest during the blowing of the fibers F 1 , F 2 with the electric field E.
  • FIG. 2 now the situation is shown, are injected at the fibers 1 by means of the nozzle D in the direction 4 in the interior I between upper mold O and lower mold U.
  • the fibers F 1 are initially not aligned despite effective electric field E in the interior I.
  • the fibers F 1 , F 2 lose kinetic energy on further penetration into the interior I and are now due to the force of the electric field E corresponding to the field lines, that is here in FIG. 2 approximately perpendicular to the mold top and bottom extending field lines of the plate-shaped electrode 2a to the plate-shaped electrode 2b aligned parallel to each other (fibers F 2 ).
  • the fibers F 2 are now deposited in their corresponding orientation on the inner sides of the upper or lower mold O, U, while the injected air escapes through the perforated upper and lower molds. If the interior I completely filled with (aligned) fibers F 2 , the fibers F 2 are connected together, such as by heat sealing. Thereafter, if necessary, the mold or the bonded fibers F 2 are cooled. The result is a solid molding that can be removed after opening the mold 1.
  • FIG. 3 In particular, the alignment of the fibers F 1 is shown, which assume the fibers F 1 in the interior I, when no electric field E in the interior I acts.
  • the fibers F 1 are arbitrarily oriented to one another and form a so-called random fiber fleece with non-rectified fibers F 1 .
  • FIG. 4a 4b and 4b show cross-sections of molded parts 5, which were once made by means of fibers F 2, which were aligned by an electric field E ( FIG. 4a ) and once a molded part 5 with non-directional fibers F 1 , which were prepared in the absence of an electric field E in the interior I. Furthermore, a force F acting from above on the molded parts 5 produced in this way is shown.
  • the fibers F 2 are aligned parallel to this acting force F
  • FIG. 4b assume no definite orientation, ie a random orientation with respect to the force F acting from above. Since the fibers F 2 in FIG. 4a are aligned parallel to the forces acting on the mold part 5 force F, the molding of the FIG.
  • FIG. 5 a mold 1 according to the invention is shown, consisting of upper mold O and lower mold U. Both forms are made in known manner from perforated wall parts which are detachably connected to each other. When the fibers are blown in, the upper mold and lower mold form a closed box. After bonding the injected fibers, this box is then opened as known.
  • a nozzle D for injecting fiber material into the inner space I of the mold 1 is arranged approximately perpendicular to this side wall.
  • the nozzle D carries an electrode 2c for static charging of the fibers F 1 , F 2 during the blowing.
  • a part of the upper mold O is formed as an electrode 2a and, accordingly, also a part of the lower mold U as an electrode 2b.
  • an electric field E can be generated by applying a voltage.
  • the voltage at the electrodes is selected such that an electric field strength of 5 kV / cm to 10 kV / cm, in particular 6 kV / cm to 8 kV / cm is formed.
  • the upper mold O and the lower mold U have sieve-like arranged holes 5, which serve that the air flow from the inner space I can escape again.
  • the fibers F 1 , F 2 are transported to the insides of the upper mold O and lower mold U and are deposited thereon, so that after completely filling the inner space I with fibers F 1 , F 2 by gluing the fibers F 1 , F 2 can be made to each other a molding.
  • the upper mold O and the lower mold U can not partially be made of conductive material, wherein the respective electrodes 2a, 2b are of course made of conductive material.
  • FIG. 6a a lower tool U of a mold 1 is shown.
  • the lower mold U has a perforated plate 5 and usually forms the negative pole. Furthermore, the lower mold U is substantially cup-shaped, wherein the edges of the lower mold U have a total of a substantially rectangular cross-section.
  • FIG. 6c is the subform U of FIG. 6a corresponding upper mold O shown, which has substantially the same structure and forms the positive pole.
  • the upper mold O is either made of a non-conductive material, on the outside of which there is an electrode 2a directly ( FIG. 6b ) or the upper mold O is itself completely formed as an electrode 2a ( FIG. 6c ) and therefore has a peripheral electrical insulation 6 disposed at the edges of the upper mold O, so that when the upper mold O is placed on the lower mold U to form an inner space I, the upper mold O and the lower mold U are electrically insulated from each other ,
  • FIG. 7 a feed line Z for a nozzle D is shown, in which the fiber material is transported in the direction R by means of air flow, in order subsequently to be transported via the nozzle D into the interior I.
  • a ring electrode 2d is arranged on the outside of the supply line Z, which charges uncharged fibers F 1 , F 2 and further strengthens already charged fibers F 1 , F 2 with respect to their charge, so that these fibers F 1 later after blowing , F 2 are aligned under the action of an electric field E in the interior I.
  • the electrode 2d is mounted directly in front of the nozzle D or an injection opening and comprises either a pipe section 2d made of metal, which is arranged in the supply line Z or the ring electrode 2d shown, which is arranged on the outside of a feed line hose Z made of plastic.
  • a pipe section 2d made of metal which is arranged in the supply line Z or the ring electrode 2d shown, which is arranged on the outside of a feed line hose Z made of plastic.
  • FIG. 8 shows the vertical section through a device 10 for pre-alignment of the fibers before the fibers enter the nozzle.
  • the alignment device consists of a circulating cover tape 11, which conveys the fibers thrown from the top - possibly after a certain separation, so that they are connected only in small flakes - to the left to a pair of feed rollers 12a, 12b.
  • feed rollers 12a, 12b These are two rollers rotating in opposite directions and arranged with a small gap parallel to one another, which are roughened on their outer circumferential surface, in particular slightly toothed. They pick up the fibers coming from the cover belt 11 and convey them further through their intermediate gap to the left.
  • at least one of the two rollers can be mounted displaceably in the vertical direction against spring force.
  • the fibers are carried along by a relatively large rotating cylinder 13.
  • This cylinder is surrounded by a small distance from approximately semi-cylindrical outer walls 14. Due to its rough, in particular toothed outer cylindrical surface, it pulls the fibers through the gap located between the cylinder 13 and the outer wall 14.
  • the fibers are gradually aligned by their friction on the outer wall 14 more or less in the rotational direction of the cylinder 13, so preferably oriented in the circumferential direction. In this orientation, the fibers then - after a half, sometimes even after one and a half revolutions of the cylinder 13 - to an output gap 15, from where the fibers are then transported to the one or more nozzles, ie in the mold 1.
  • the present invention has the advantage that in a simple manner, the fibers for the production of the molding can be aligned in one or more preferred directions, so that the fibers are arranged in a certain direction in the finished molding to desired properties of the molding in its intended use to reinforce. In particular, this allows the strength, the elasticity and, as a result, the service life of the molded part to be specifically influenced.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Claims (8)

  1. Dispositif de fabrication de pièces moulées tridimensionnelles constituées par des fibres (F1, F2), se prêtant notamment à la mise en oeuvre d'un procédé de fabrication de pièces moulées en un matériau fibreux,
    comprenant
    • un moule (1) en plusieurs parties comportant au moins un espace intérieur (I), la face intérieure dudit moule (1) déterminant, au moins partiellement, le profil de la pièce moulée à fabriquer,
    • une ou plusieurs buse(s) (D), destinée(s) à insuffler les fibres (F1, F2) dans l'espace intérieur (I),
    • des orifices (5) de passage d'air, pratiqués dans le moule (1) en vue de l'échappement de l'air hors de l'espace intérieur (I) et de l'accumulation des fibres contre la face intérieure dudit moule (1),
    • des moyens de liaison des fibres (F1, F2), en vue de la fabrication de la pièce moulée, et
    • des moyens (2a, 2b) de génération d'un ou plusieurs champs électrique(s) (E), qui exposent au moins en partie l'espace intérieur (I) à un ou plusieurs champs électrique(s) (E), de sorte que, lors de l'insufflation dans le moule (1), les fibres (F1, F2) sont orientées au moins partiellement le long des directions respectives desdits champs électriques (E) qui coïncident, au moins approximativement, avec une ou plusieurs direction(s) préférentielle(s) souhaitée(s) desdites fibres (F1, F2) dans la partie de moulage,
    caractérisé par le fait
    qu'un appareil (10) d'orientation des fibres, placé en amont de la ou des buse(s) (D), présente un élément convoyeur mobile (13) qui guide les fibres (F1, F2), par frottement, le long d'une paroi (14) située en vis-à-vis.
  2. Dispositif selon la revendication 1,
    caractérisé par le fait que
    l'élément convoyeur mobile (13) est réalisé sous la forme d'un cylindre rotatif.
  3. Dispositif selon au moins l'une des revendications 1-2,
    caractérisé par le fait que
    des moyens (2d), conférant une charge électrique, sont implantés sur la buse (D) à présence minimale et/ou sur un conduit d'amenée (Z) dédié à ladite buse (D) à présence minimale.
  4. Dispositif selon au moins l'une des revendications 1-3,
    caractérisé par le fait que
    les moyens (2a, 2b) de génération de champs électriques (E) incluent des électrodes (2a, 2b) en forme d'anneaux, de platines et/ou de barrettes.
  5. Dispositif selon au moins l'une des revendications 1-4,
    caractérisé par le fait
    qu'au moins une partie du moule (1) en plusieurs parties est réalisée, au moins partiellement, sous la forme d'une électrode (2a, 2b).
  6. Dispositif selon au moins l'une des revendications 1-5,
    caractérisé par le fait que
    des électrodes (2a, 2b) sont placées sur les faces extérieures du moule (1) en plusieurs parties et, en particulier, ledit moule (1) en plusieurs parties est partiellement fabriqué en un matériau non conducteur.
  7. Dispositif selon au moins l'une des revendications 1-6,
    caractérisé par le fait
    qu'au moins une buse (D) est réalisée sous la forme d'une électrode (2a, 2b).
  8. Dispositif selon au moins l'une des revendications 1-7,
    caractérisé par le fait que
    des moyens (6) d'isolation électrique sont notamment interposés entre des parties du moule (1) en plusieurs parties.
EP10010798.6A 2009-10-02 2010-09-27 Dispositif et procédé de fabrication de pièces de formage à partir de matériaux en fibres Active EP2305869B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102009048001A DE102009048001A1 (de) 2009-10-02 2009-10-02 Vorrichtung und Verfahren zum Herstellen von Formteilen aus Fasermaterial

Publications (2)

Publication Number Publication Date
EP2305869A1 EP2305869A1 (fr) 2011-04-06
EP2305869B1 true EP2305869B1 (fr) 2013-06-12

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Country Status (5)

Country Link
EP (1) EP2305869B1 (fr)
JP (1) JP5691360B2 (fr)
CN (1) CN102031642B (fr)
DE (1) DE102009048001A1 (fr)
ES (1) ES2426236T3 (fr)

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CA2459393A1 (fr) * 2001-09-03 2003-03-13 Teijin Limited Procede et appareil de moulage d'un agregat de fibres
DE102005006273A1 (de) * 2004-04-21 2005-11-10 Trützschler GmbH & Co KG Vorrichtung zum Verfestigen eines förderbaren Faservlieses, z. B. aus Baumwolle, Chemiefasern o. dgl.
DE102007054424A1 (de) 2007-11-13 2009-05-28 Robert Bürkle GmbH Vorrichtung zum Herstellen von Formteilen aus Fasermaterial
JP5225827B2 (ja) * 2008-12-19 2013-07-03 パナソニック株式会社 ナノファイバ製造装置

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102015200275A1 (de) 2015-01-12 2016-07-14 Hp Pelzer Holding Gmbh 3-dimensionales hochfestes Faserverbundbauteil und Verfahren zu seiner Herstellung
US20170348921A1 (en) * 2015-01-12 2017-12-07 Hp Pelzer Holding Gmbh 3-dimensional high-strength fiber composite component and method for producing same
US10322551B2 (en) 2015-01-12 2019-06-18 Adler Pelzer Holding Gmbh 3-Dimensional high-strength fiber composite component and method for producing same

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DE102009048001A1 (de) 2011-04-14
JP5691360B2 (ja) 2015-04-01
CN102031642B (zh) 2015-12-16
ES2426236T3 (es) 2013-10-22
EP2305869A1 (fr) 2011-04-06
JP2011080188A (ja) 2011-04-21
CN102031642A (zh) 2011-04-27

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