WO2004094130A1 - Plastic hollow bodies and method for the production thereof - Google Patents

Plastic hollow bodies and method for the production thereof Download PDF

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Publication number
WO2004094130A1
WO2004094130A1 PCT/EP2004/003173 EP2004003173W WO2004094130A1 WO 2004094130 A1 WO2004094130 A1 WO 2004094130A1 EP 2004003173 W EP2004003173 W EP 2004003173W WO 2004094130 A1 WO2004094130 A1 WO 2004094130A1
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WO
WIPO (PCT)
Prior art keywords
semi
finished products
films
plastic
foamed
Prior art date
Application number
PCT/EP2004/003173
Other languages
German (de)
French (fr)
Inventor
Jürgen BRUNING
Maik Ziegler
Original Assignee
Fagerdala Deutschland Gmbh
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 Fagerdala Deutschland Gmbh filed Critical Fagerdala Deutschland Gmbh
Publication of WO2004094130A1 publication Critical patent/WO2004094130A1/en

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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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/266—Auxiliary operations after the thermoforming operation
    • B29C51/267—Two sheets being thermoformed in separate mould parts and joined together while still in the mould
    • 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
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0053—Moulding articles characterised by the shape of the surface, e.g. ribs, high polish
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/06905—Using combined techniques for making the preform
    • B29C49/0691—Using combined techniques for making the preform using sheet like material, e.g. sheet blow-moulding from joined sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
    • B60H1/00—Heating, cooling or ventilating [HVAC] devices
    • B60H1/00507—Details, e.g. mounting arrangements, desaeration devices
    • B60H1/00557—Details of ducts or cables
    • B60H1/00564—Details of ducts or cables of air ducts
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0822—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using IR radiation
    • 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
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/006—Using vacuum
    • 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
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/007—Using fluid under pressure
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/42—Moulds or cores; Details thereof or accessories therefor characterised by the shape of the moulding surface, e.g. ribs or grooves
    • B29C33/424—Moulding surfaces provided with means for marking or patterning
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/22—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor using multilayered preforms or parisons
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/48—Moulds
    • B29C49/4823—Moulds with incorporated heating or cooling means
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/30—Moulds
    • B29C51/36—Moulds specially adapted for vacuum forming, Manufacture thereof
    • B29C51/365—Porous moulds
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/022—Particular heating or welding methods not otherwise provided for
    • B29C65/028—Particular heating or welding methods not otherwise provided for making use of inherent heat, i.e. the heat for the joining comes from the moulding process of one of the parts to be joined
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • 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
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof

Definitions

  • the invention relates to foamed plastic hollow bodies and a method for their production.
  • thermoplastic, non-foamed polyolefin films It is known to heat thermoplastic, non-foamed polyolefin films and to deep-draw them under the application of vacuum on one mold half in order to achieve the desired shape. For example, packaging for food is produced in this way.
  • semi-finished foam products for example from polystyrene foam
  • shaping of semi-finished foam products for example from polystyrene foam
  • semi-finished products are networked! Polyethylene S' ⁇ ha ⁇ jmst ⁇ ff products such as ermsoüermatten manufactured by heating and subsequent pressing in a contour-giving shape.
  • blow molding a preform or a tube extrudate is inflated within a cavity by means of a blowing lance (see, for example, DE-A-35 12 973 and EP-B1-0 545 055).
  • rotational molding thermoplastic powder or granules are introduced into a heatable tool and by rotating the tool, powders or granules are evenly distributed and melted on the outer skin.
  • solid hollow bodies such as barrels or canisters as well as three-dimensionally shaped decorative layers, preferably based on polyvinyl chloride (PVC), are produced, for example for instrument panels.
  • DE-A-100 10 900 describes a combined extrusion-pressing process in which half-shells are produced from preforms, which are then welded into hollow bodies. However, the method is only suitable for components with solid walls.
  • Hollow body described in which two semi-finished foam products are connected to each other, a fluid is introduced between the semi-finished products and hollow bodies are formed in a tool.
  • Disadvantages of this method are the thinning in the higher stretched areas, the poor surface quality inside and on the surface facing the tool, residual amounts of the fluid, the need for temperature control of the fluid and a limited deformability of the foam films.
  • thermoforming / deep drawing Processes such as thermoforming / deep drawing are primarily suitable for
  • thermoforming for example, by printing the ventilation holes.
  • the side that does not abut the mold half also shows a rough surface structure due to the melting of the polymer.
  • the currently used cross-linked or partially cross-linked polyolefin foam films can only be thermoformed to a limited extent, since they are cross-linked
  • the invention is therefore based on the object of providing a method for producing foamed plastic hollow bodies which, by means of a simpler process control and by means of simple and inexpensive system technology, enables economical production of low-density foamed plastic hollow bodies, without being restricted to certain geometries of the hollow bodies by means of limited deep-drawing rates , with which the production of foamed plastic hollow bodies with a smooth, visually appealing surface is possible, which can be completely reused (recycled).
  • single or multi-layer uncrosslinked polypropylene foam films are preferably used as plastic semi-finished products made of foamed, thermoplastic, which particularly preferably also in combination with non-foamed plastic films, fabrics, Knitted fabrics, nonwovens, glass fibers, decorative and cover layers can be used.
  • the uncrosslinked polypropylene foam films with laminated or coextruded unfoamed films are preferably used.
  • Polypropylene foam film is at least partially bonded to laminated decorative layers, in particular decorative films or textile layers. Inserts or decorative elements, such as labeled foils, are particularly preferably formed during the process, in particular if it is designed as a thermoforming process.
  • the tools are designed in such a way that the tool halves, the shape of which corresponds to the outer contour of the hollow body to be produced, consist of a porous material or are perforated. Porous or perforated resins, porous or perforated metals, metal grids, sintered metals or combinations thereof can be used here.
  • the semi-finished products to be reshaped are e.g. over the pores or perforations in the tool halves.
  • Foam foils initially held in one half of the mold by means of negative pressure, which ensures that the foil is fixed and the wrinkle-free adaptation to the tool contours is ensured.
  • the adaptation to the tool contour can be done by regulating the negative pressure, which causes the foam sheet to deform.
  • the semi-finished products can be held over clamping devices, which preferably allow the material to be tracked during the deep-drawing process and / or ensure the seal between the semi-finished product and the mold half.
  • a counter-holder or a tool core can additionally be used, which is pressed into the perforated or porous mold half over the film for forming.
  • the semi-finished products to be formed can be formed before and during the forming process Forming process are heated, for example by infrared radiation.
  • the semi-finished products to be formed are preferably heated to a temperature of 150 to 250 ° C.
  • the mold halves can be tempered.
  • the semi-finished plastic products are at least partially integrally welded to one another at the parting plane of the tool halves. This is done by merging the mold halves and tempering the semi-finished products at the points to be welded.
  • An essential feature of the method according to the invention is the use of thermal energy for the simultaneous thermoforming and welding of the semi-finished products at their contact points. The closing of the mold halves or the merging of the later connection points is controlled in time with the start of the thermoforming in such a way that an ideal thermoforming or stretching of the semi-finished products is made possible, possibly with tracking of the foam films used as semi-finished products, and the connection points nevertheless have a sufficient temperature have for welding.
  • the heating of the deep-drawn semi-finished products to be formed which is necessary for the forming, can be achieved via heating devices such as infrared radiators outside and / or inside the tool and / or by tempering the tool cavity. Furthermore, the imaging accuracy of the tool surface in the foam film can be controlled via the mold temperature control and skin formation or compaction can be generated on the film surface.
  • the tool halves are preferably closed simultaneously with or immediately after a negative pressure is applied.
  • the vacuum is at least partially maintained in the tool halves during welding. Furthermore, this can also be done by regulating the pressure in the tool Refill material to prevent cracks and changes in wall thickness in areas that need to be shaped.
  • a lance is introduced into the cavity of the hollow body in order to either build up an overpressure in the interior in order to increase the shape and surface quality, or to produce a vacuum which increases the density of the foam sheet by increasing the wall thickness decreased and the bending stiffness increased.
  • the wall thickness and thus the bending stiffness decrease in a normal thermoforming or deep-drawing process.
  • the foamed structure enables by applying negative pressure on both sides of the heated foam sheet, i.e. in the cavity and on the tool, increasing or at least reducing the wall thickness to its original thickness.
  • the surfaces of at least one of the two tool halves are preferably at least partially structured, the structure preferably being in the form of a grain, for example a leather grain, or a textile structure or lattice structure and by molding the tools from a negative model with a corresponding surface structure or by direct insertion the structure in the tool surface using common methods, e.g. cutting processes, etching processes, spark erosion processes, laser processes.
  • common methods e.g. cutting processes, etching processes, spark erosion processes, laser processes.
  • a major advantage of the method according to the invention is the cost-effective production of hollow bodies and shaped bodies which at least partially contain cavities.
  • a method is provided which also enables the production of hollow bodies with foamed walls of low density. By controlling the negative pressure on the tool wall in combination with the temperature control of the foam films and / or the tools, a reproducible wall thickness of the hollow foam body with a high-quality surface is obtained.
  • extremely light and heat-insulating air guiding elements and other parts for motor vehicle interiors can advantageously be produced.
  • Double-walled, heat-insulating, lightweight containers for the food industry with a high-quality, hygienically perfect surface can also be produced.
  • FIG. 1 is a schematic representation of a heating device for foam films
  • FIG. 2 to Figure 6 show schematically different stages of a preferred embodiment of the method according to the invention for producing a foamed plastic hollow body from non-crosslinked polypropylene foam films, using porous tool halves.
  • two polypropylene foam films (1, 2) are heated to a temperature between 150 ° C. and 210 ° C. in an infrared heating device (10, 20).
  • the heated foam sheets (1, 2) are transferred to a porous forming tool (FIG. 2) with the two mold halves (5, 6) made of commercially available pore resin of the Metapor ® brand and by applying a vacuum (symbolized by the arrows 3, 4 ) on the porous
  • the foam foils (1, 2) are completely reshaped and adapted to the inner contour of the tool halves (5, 6).
  • Vacuum on the tool halves (5, 6) is at least partially maintained in order to avoid warping of the foils.
  • the tool halves (5, 6) are opened after the negative pressure has been released (FIG. 6), after which the molded part (30), a hollow body made of foamed polypropylene, is made from the foam foils (1, 2).

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)

Abstract

The invention relates to foamed plastic hollow bodies and to a method for the production thereof. To this end, thermoplastic semifinished products, preferably extruded semifinished products made of uncrosslinked polypropylene foam film, are partially reshaped and joined by pressure and/or temperature to form a hollow body while using porous or perforated mold halves, on each of which underpressure exists.

Description

Kunststoffhohlkörper und Verfahren zu deren Herstellung Hollow plastic body and process for its production
Die Erfindung betrifft geschäumte Kunststoffhohlkörper und ein Verfahren zu deren Herstellung.The invention relates to foamed plastic hollow bodies and a method for their production.
Es ist bekannt, thermoplastische ungeschäumte Polyolefinfolien zu erhitzen und unter Anlegen von Vakuum an einer Formhälfte tiefzuziehen, um die gewünschte Formgebung zu erreichen. Beispielsweise werden Verpackungen für Lebensmittel auf diese Weise hergestellt.It is known to heat thermoplastic, non-foamed polyolefin films and to deep-draw them under the application of vacuum on one mold half in order to achieve the desired shape. For example, packaging for food is produced in this way.
Des weiteren ist das Umformen von Schaumstoff-Halbzeugen, beispielsweise aus Polystyrol-Schaumstoff, für Verpackungsschalen für Lebensmittel durch Erhitzen und anschließendes Umformen in gekühlten massiven Aluminiumwerkzeugen bekannt. Ebenso werden aus Halbzeugen aus vernetzten! Polyethylen- S'σhaτjmstσff Produkte wie ϊsoüermatten durch Erhitzen und nachträgliches Verpressen in einer konturgebenden Form hergestellt.Furthermore, the shaping of semi-finished foam products, for example from polystyrene foam, for packaging trays for food by heating and subsequent shaping in cooled solid aluminum tools is known. Likewise, semi-finished products are networked! Polyethylene S'σhaτjmstσff products such as ermsoüermatten manufactured by heating and subsequent pressing in a contour-giving shape.
Zur Herstellung von Hohlkörpern sind Verfahren wie Blasformen oder Rotationsformen bekannt. Beim Blasformen wird ein Vorformling oder ein Schlauchextrudat mittels einer Blaslanze innerhalb einer Kavität aufgeblasen (vgl. z.B. DE-A-35 12 973 und EP-B1-0 545 055). Beim Rotationsformen werden thermoplastische Kunststoffpulver oder -granulate in ein beheizbares Werkzeug eingebracht und durch Rotationsbewegung des Werkzeugs werden Pulver oder Granulate gleichmäßig an der Außenhaut verteilt und angeschmolzen. Auf diese Weise werden sowohl massive Hohlkörper wie Tonnen oder Kanister als auch dreidimensional geformte Dekorschichten, vorzugsweise auf Basis von Polyvinyl- chlorid (PVC), beispielsweise für Instrumententafeln hergestellt. In DE-A-100 10 900 wird ein kombiniertes Extrusions-Preß- Verfahren beschrieben, bei dem aus Vorformlingen Halbschalen hergestellt werden, die anschließend zu Hohlkörpern verschweißt werden. Das Verfahren eignet sich jedoch nur für Bauteile mit massiven Wandungen.Methods such as blow molding or rotary molding are known for producing hollow bodies. In blow molding, a preform or a tube extrudate is inflated within a cavity by means of a blowing lance (see, for example, DE-A-35 12 973 and EP-B1-0 545 055). In rotational molding, thermoplastic powder or granules are introduced into a heatable tool and by rotating the tool, powders or granules are evenly distributed and melted on the outer skin. In this way, solid hollow bodies such as barrels or canisters as well as three-dimensionally shaped decorative layers, preferably based on polyvinyl chloride (PVC), are produced, for example for instrument panels. DE-A-100 10 900 describes a combined extrusion-pressing process in which half-shells are produced from preforms, which are then welded into hollow bodies. However, the method is only suitable for components with solid walls.
In DE-A-40 06 729 wird ein Verfahren zur Herstellung geschäumterDE-A-40 06 729 describes a process for producing foamed
Hohlkörper beschrieben, bei dem zwei Schaumstoffhalbzeuge miteinander verbunden werden, ein Fluid zwischen die Halbzeuge eingebracht wird und in einem Werkzeug Hohlkörper ausgeformt werden. Nachteilig sind bei diesem Verfahren die Ausdünnung an den höher verstreckten Bereichen, die schlechte Ober- flächenqualität innen und an der zum Werkzeug gerichteten Oberfläche, Restmengen des Fluids, der Temperierbedarf des Fluids sowie eine begrenzte Verformbarkeit der Schaumstoffolien.Hollow body described, in which two semi-finished foam products are connected to each other, a fluid is introduced between the semi-finished products and hollow bodies are formed in a tool. Disadvantages of this method are the thinning in the higher stretched areas, the poor surface quality inside and on the surface facing the tool, residual amounts of the fluid, the need for temperature control of the fluid and a limited deformability of the foam films.
Verfahren wie Thermoformen/Tiefziehen eignen sich in erster Linie zurProcesses such as thermoforming / deep drawing are primarily suitable for
Formgebung massiver oder geschäumter Kunststoffolien; Hohlkörper sind bisher nicht damit gefertigt worden. Zur Herstellung von Hohlkörpern wird dasShaping of solid or foamed plastic films; Hollow bodies have not previously been produced with it. For the production of hollow bodies
Rotationsformen, welches relativ lange Zykluszeiten mit sich bringt, und dasRotational forms, which entails relatively long cycle times, and that
Blasformen, welches eine teure Anlagentechnik erfordert, eingesetzt.Blow molding, which requires expensive plant technology, is used.
Sonderverfahren oder Verfahrenskombinationen, wie das Twin-Sheet- Verfah-fεa oder das is DE-A-100 10 9-00- bescbrieb ac Verfahre», siad- a*ιr ZΪK- Weiterverarbeitung von ungeschäumten Kunststoffplatten zu Hohlkörpern geeignet.Special processes or process combinations, such as the twin-sheet process or the DE-A-100 10 9-00- description of the process, are suitable for further processing of non-foamed plastic sheets into hollow bodies.
Verfahren gemäß DE-A-35 12 973 und DE-A-40 06 729 beschreiben die Herstellung von Schaumstoffhohlkörpern, arbeiten jedoch nach einem ähnlichen Prinzip wie das Blasformen und bringen aufgrund der Prozeßführung und Anlagentechnik geometrische Einschränkungen der Hohlkörper mit sich.Processes according to DE-A-35 12 973 and DE-A-40 06 729 describe the production of hollow foam bodies, but work according to a similar principle to blow molding and, due to the process control and plant technology, entail geometric limitations of the hollow bodies.
Allgemein wird beim Thermoformen beispielsweise durch Abdrücke der Belüftungslöcher eine mangelhafte Oberflächenqualität erzielt. Die nicht an der Formhälfte anliegende Seite zeigt durch Aufschmelzung des Polymers ebenfalls eine rauhe Oberflächenstruktur. Die derzeit eingesetzten vernetzten oder teilvernetzten Polyolefinschaumfolien sind des weiteren nur eingeschränkt tiefziehfähig, da ein solches vernetztesIn general, a poor surface quality is achieved in thermoforming, for example, by printing the ventilation holes. The side that does not abut the mold half also shows a rough surface structure due to the melting of the polymer. The currently used cross-linked or partially cross-linked polyolefin foam films can only be thermoformed to a limited extent, since they are cross-linked
Polymer bei erhöhter Temperatur nicht mehr ausreichend in einen viskosen oder viskoelastischen Zustand überführbar ist und somit keine größeren Tiefziehraten wie bei einem unvernetzten Polymer möglich sind.It is no longer possible to convert the polymer sufficiently into a viscous or viscoelastic state at elevated temperature and thus no higher deep-drawing rates are possible than with an uncrosslinked polymer.
Der Erfindung liegt daher die Aufgabe zugrunde, ein Verfahren zur Herstellung geschäumter Kunststoffhohlkörper bereitzustellen, welches über eine einfachere Prozeßfiihrung und mittels einfacher und kostengünstiger Anlagentechnik eine wirtschaftliche Herstellung geschäumter Kunststoffhohlkörper nied- riger Dichte ermöglicht, und zwar ohne Beschränkung auf bestimmte Geometrien der Hohlkörper durch eingeschränkte Tiefziehraten, mit dem die Herstellung geschäumter Kunststoffhohlkörper mit glatter, optisch ansprechender Oberfläche gelingt, die sich vollständig wiederverwerten (recyceln) lassen.The invention is therefore based on the object of providing a method for producing foamed plastic hollow bodies which, by means of a simpler process control and by means of simple and inexpensive system technology, enables economical production of low-density foamed plastic hollow bodies, without being restricted to certain geometries of the hollow bodies by means of limited deep-drawing rates , with which the production of foamed plastic hollow bodies with a smooth, visually appealing surface is possible, which can be completely reused (recycled).
Diese Aufgabe wird erfindungsgemäß dadurch gelöst, daß mindestens zwei Halbzeuge aus geschäumtem, thermoplastischem Kunststoff über poröse oder perforierte Werkzeughälften, an denen jeweils Unterdruck anliegt, umgeformt werden und über Druck und/oder Temperatur zu einem Hohlkörper stoffschlüssig verbunden werden.This object is achieved in that at least two semi-finished products made of foamed, thermoplastic plastic are formed over porous or perforated mold halves, each of which is under vacuum, and cohesively connected to a hollow body via pressure and / or temperature.
Auf diese Weise lass n sich überraschend einfach -anά wirtschaftlich geschäumte Kunststoffhohlkörper beliebiger geometrischer Form und Größe mit niedriger Dichte herstellen, die eine glatte, optisch ansprechende Oberfläche von hoher Güte aufweisen, vollständig wiederverwertbar sind und sich deshalb besonders zur Herstellung von Isolierbehältern für den Lebensmittelbereich und von hochwertigen Kraftfahrzeuginnenausstattungselementen, beispielsweise Luftfüh- rungselementen, eignen.In this way, surprisingly simple - economically foamed plastic hollow bodies of any geometric shape and size with low density can be produced, which have a smooth, visually appealing surface of high quality, are completely recyclable and are therefore particularly suitable for the production of insulating containers for the food sector and of high-quality automotive interior elements, for example air guidance elements.
Als Kunststoffhalbzeuge aus geschäumtem, thermoplastischem Kunststoff werden erfindungsgemäß vorzugsweise ein- oder mehrlagige unvernetzte Polypropylenschaumfolien, sogenannte XPP-Folien, verwendet, die besonders bevorzugt auch in Kombination mit ungeschäumten Kunststoffolien, Geweben, Gewirken, Nonwovens, Glasfasern, Dekor- und Deckschichten eingesetzt werden können.According to the invention, single or multi-layer uncrosslinked polypropylene foam films, so-called XPP films, are preferably used as plastic semi-finished products made of foamed, thermoplastic, which particularly preferably also in combination with non-foamed plastic films, fabrics, Knitted fabrics, nonwovens, glass fibers, decorative and cover layers can be used.
Vorzugsweise werden die unvernetzten Polypropylenschaumfolien mit aufkaschierten oder koextrudierten ungeschäumten Folien eingesetzt.The uncrosslinked polypropylene foam films with laminated or coextruded unfoamed films are preferably used.
Bei anderen bevorzugten Ausführungsformen ist die unvernetzteIn other preferred embodiments, the is uncrosslinked
Polypropylenschaumfolie zumindest teilweise mit aufkaschierten Dekorschichten, insbesondere Dekorfolien oder textilen Schichten, verbunden. Besonders bevorzugt werden Einlegeteile oder Dekorelemente wie beschriftete Folien während des Prozesses, insbesondere wenn er als Thermoformierprozeß ausge- staltet ist, angeformt.Polypropylene foam film is at least partially bonded to laminated decorative layers, in particular decorative films or textile layers. Inserts or decorative elements, such as labeled foils, are particularly preferably formed during the process, in particular if it is designed as a thermoforming process.
Zur Formgebung und Verarbeitung der Halbzeuge werden die Werkzeuge derart gestaltet, daß die Werkzeughälften, deren Form der äußeren Kontur des herzustellenden Hohlkörpers entspricht, aus einem porösen Werkstoff bestehen oder perforiert sind. Zum Einsatz können hierbei poröse oder perforierte Harze, poröse oder perforierte Metalle, Metallgitter, Sintermetalle oder Kombinationen daraus kommen. Über die Poren bzw. Perforationen in den Werkzeughälften werden die umzuformenden Halbzeuge, z.B. Schaumfolien, mittels Unterdrucks zunächst in einer Werkzeughälfte gehalten, wodurch eine Fixierung der Folie und eine faltenfreie Anpassung derselben an die Werkzeugkonturen gewährleistet wird. Das Anpassen an die Werkzeugkontur kann durch Regelung des Unterdrucks erfolgen, der eine Verformung der Schaumstoffolie bewirkt. Dabei können die Halbzeuge über Spannvorrichtungen gehalten werden, die vorzugsweise eine Nachführung des Materials während des Tiefziehprozesses erlauben und/oder die Abdichtung zwischen Halbzeug und Werkzeughälfte gewährleisten.For the shaping and processing of the semi-finished products, the tools are designed in such a way that the tool halves, the shape of which corresponds to the outer contour of the hollow body to be produced, consist of a porous material or are perforated. Porous or perforated resins, porous or perforated metals, metal grids, sintered metals or combinations thereof can be used here. The semi-finished products to be reshaped are e.g. over the pores or perforations in the tool halves. Foam foils, initially held in one half of the mold by means of negative pressure, which ensures that the foil is fixed and the wrinkle-free adaptation to the tool contours is ensured. The adaptation to the tool contour can be done by regulating the negative pressure, which causes the foam sheet to deform. The semi-finished products can be held over clamping devices, which preferably allow the material to be tracked during the deep-drawing process and / or ensure the seal between the semi-finished product and the mold half.
Bei einer weiteren Variante des erfindungsgemäßen Verfahrens kann zusätzlich ein Gegenhalter oder ein Werkzeugkern verwendet werden, der zur Umformung über der Folie in die perforierte oder poröse Werkzeughälfte gedrückt wird. Zur Unterstützung des Umformprozesses können die umzuformenden Halbzeuge vor dem Umformprozeß und/oder während des Umformprozesses erwärmt werden, beispielsweise durch Infrarotstrahlung. Die umzuformenden Halbzeuge werden vorzugsweise auf eine Temperatur von 150 bis 250°C erwärmt.In a further variant of the method according to the invention, a counter-holder or a tool core can additionally be used, which is pressed into the perforated or porous mold half over the film for forming. To support the forming process, the semi-finished products to be formed can be formed before and during the forming process Forming process are heated, for example by infrared radiation. The semi-finished products to be formed are preferably heated to a temperature of 150 to 250 ° C.
Bei einer bevorzugten Ausfuhrungsform der Erfindung können die Werk- zeughälften temperiert werden.In a preferred embodiment of the invention, the mold halves can be tempered.
Während des Umformprozesses oder in einem nachfolgenden Schritt werden die Kunststoffhalbzeuge, die gegebenenfalls auch vorgeformt sein können, an der Trennebene der Werkzeughälften miteinander mindestens teilweise stoffschlüssig verschweißt. Dies erfolgt durch Zusammenführen der Werkzeughälften und Temperierung der Halbzeuge an den zu verschweißenden Stellen. Ein wesentliches Merkmal des erfindungsgemäßen Verfahrens ist die Nutzung der Wärmeenergie zur gleichzeitigen Thermoformierung und Verschweißung der Halbzeuge an ihren Kontaktstellen. Das Schließen der Werkzeughälften bzw. das Zusammenführen der späteren Verbindungsstellen wird zeitlich mit dem Beginn der Thermoformierung so gesteuert, daß eine ideale Thermoformierung bzw. Verstreckung der Halbzeuge, ggf. unter Nachführung der als Halbzeuge verwendeten Schaumfolien, ermöglicht wird und die Verbindungsstellen dennoch eine ausreichende Temperatur zur Verschweißung aufweisen.During the forming process or in a subsequent step, the semi-finished plastic products, which may also be preformed if necessary, are at least partially integrally welded to one another at the parting plane of the tool halves. This is done by merging the mold halves and tempering the semi-finished products at the points to be welded. An essential feature of the method according to the invention is the use of thermal energy for the simultaneous thermoforming and welding of the semi-finished products at their contact points. The closing of the mold halves or the merging of the later connection points is controlled in time with the start of the thermoforming in such a way that an ideal thermoforming or stretching of the semi-finished products is made possible, possibly with tracking of the foam films used as semi-finished products, and the connection points nevertheless have a sufficient temperature have for welding.
Die für das Umformen notwendige Erwärmung der tiefzuziehenden umzu- formenden Halbzeuge kann über Heizeinrichtungen wie beispielsweise Infrarot- Strahler außerhalb und/oder innerhalb des Werkzeugs und/oder durch Temperieren der Werkzeugkavität erreicht werden. Ferner kann über die Werkzeugtemperierung die Abbildungsgenauigkeit der Werkzeugoberfläche in der Schaumfolie gesteuert werden und eine Hautbildung bzw. Verdichtung auf der Folienoberfläche erzeugt werden.The heating of the deep-drawn semi-finished products to be formed, which is necessary for the forming, can be achieved via heating devices such as infrared radiators outside and / or inside the tool and / or by tempering the tool cavity. Furthermore, the imaging accuracy of the tool surface in the foam film can be controlled via the mold temperature control and skin formation or compaction can be generated on the film surface.
Vorzugsweise werden die Werkzeughälften gleichzeitig mit oder unmittelbar nach dem Anlegen eines Unterdrucks geschlossen. Während der Verschweißung wird der Unterdruck zumindest teilweise in den Werkzeughälften aufrechterhalten. Ferner kann auch über eine Regelung des Drucks im Werkzeug das Material nachfließen, um Rissen und Wandstärkeänderungen in stark umzuformenden Bereichen vorzubeugen.The tool halves are preferably closed simultaneously with or immediately after a negative pressure is applied. The vacuum is at least partially maintained in the tool halves during welding. Furthermore, this can also be done by regulating the pressure in the tool Refill material to prevent cracks and changes in wall thickness in areas that need to be shaped.
Bei einer weiteren Ausfulirungsform der Erfindung wird eine Lanze in den entstehenden Hohlraum des Hohlkörpers eingeführt, um entweder einen Über- druck im Inneren aufzubauen, um die Ausformung und Oberflächenqualität zu erhöhen, oder aber einen Unterdruck herzustellen, der die Dichte der Schaumfolie durch Zunahme der Wandstärke erniedrigt und die Biegesteifigkeit erhöht. Insbesondere an den hochverstreckten Bereichen wird bei einem normalen Thermoformier- oder Tiefziehprozeß die Wandstärke und somit die Biege- steifigkeit geringer. Die geschäumte Struktur ermöglicht durch Anlegen von Unterdruck an beiden Seiten der erhitzten Schaumfolie, d.h. im Hohlraum und am Werkzeug, eine Vergrößerung oder zumindest Rückführung der Wandstärke auf ihre ursprüngliche Dicke.In a further embodiment of the invention, a lance is introduced into the cavity of the hollow body in order to either build up an overpressure in the interior in order to increase the shape and surface quality, or to produce a vacuum which increases the density of the foam sheet by increasing the wall thickness decreased and the bending stiffness increased. Especially in the highly stretched areas, the wall thickness and thus the bending stiffness decrease in a normal thermoforming or deep-drawing process. The foamed structure enables by applying negative pressure on both sides of the heated foam sheet, i.e. in the cavity and on the tool, increasing or at least reducing the wall thickness to its original thickness.
Die Oberflächen von zumindest einer der beiden Werkzeughälften werden vorzugsweise mindestens teilweise strukturiert, wobei die Struktur vorzugsweise in Form einer Narbung, beispielsweise einer Ledernarbung, oder einer Textil- struktur oder Gitterstruktur vorliegt und durch Abformung der Werkzeuge von einem Negativmodell mit entsprechender Oberflächenstruktur oder durch direktes Einbringen der Struktur in die Werkzeugoberfläche mittels gängiger Verfahren, z.B. spanender Verfahren, Ätzverfahren, Funkenerosionsverfahren, Laserverfahren, erzeugt wird.The surfaces of at least one of the two tool halves are preferably at least partially structured, the structure preferably being in the form of a grain, for example a leather grain, or a textile structure or lattice structure and by molding the tools from a negative model with a corresponding surface structure or by direct insertion the structure in the tool surface using common methods, e.g. cutting processes, etching processes, spark erosion processes, laser processes.
Ein wesentlicher Vorteil des erfindungsgemäßen Verfahrens ist die kostengünstige Herstellung von Hohlkörpern und Formkörpern, die zumindest teilweise Hohlräume enthalten. Es wird ein Verfahren bereitgestellt, welches auch die Herstellung von Hohlkörpern mit geschäumten Wandungen niedriger Dichte ermöglicht. Über die Regelung des Unterdrucks an der Werkzeugwand in Kombination mit der Temperierung der Schaumfolien und/oder der Werkzeuge wird eine reproduzierbare Wanddicke der Schaumstoffhohlkörper mit qualitativ hochwertiger Oberfläche erhalten. Auf die beschriebene Weise können vorteilhaft extrem leichte und wärmeisolierende Luftführungselemente und andere Teile für die Kraftfahrzeuginnenausstattung hergestellt werden. Ebenso können doppelwandige, wärmeisolierende, leichte Behälter für die Nahrungsmittelindustrie mit hochwertiger, hygienisch einwandfreier Oberfläche hergestellt werden.A major advantage of the method according to the invention is the cost-effective production of hollow bodies and shaped bodies which at least partially contain cavities. A method is provided which also enables the production of hollow bodies with foamed walls of low density. By controlling the negative pressure on the tool wall in combination with the temperature control of the foam films and / or the tools, a reproducible wall thickness of the hollow foam body with a high-quality surface is obtained. In the manner described, extremely light and heat-insulating air guiding elements and other parts for motor vehicle interiors can advantageously be produced. Double-walled, heat-insulating, lightweight containers for the food industry with a high-quality, hygienically perfect surface can also be produced.
Die Erfindung wird nachfolgend anhand der Zeichnung näher erläutert:The invention is explained in more detail below with reference to the drawing:
- Figur 1 ist die schematische Darstellung einer Heizeinrichtung für Schaumfolien;- Figure 1 is a schematic representation of a heating device for foam films;
- Figur 2 bis Figur 6 zeigen schematisch verschiedene Stadien einer bevorzugten Ausführungsform des erfindungsgemäßen Verfahrens zur Herstellung eines geschäumten Kunststoffhohlkörpers aus unvernetzten Polypropylenschaumfolien, unter Verwendung poröser Werkzeughälften.- Figure 2 to Figure 6 show schematically different stages of a preferred embodiment of the method according to the invention for producing a foamed plastic hollow body from non-crosslinked polypropylene foam films, using porous tool halves.
Ausführungsbeispiel :Design example:
Wie in Figur 1 schematisch dargestellt, werden in einer Infrarot-Heizein- richtung (10, 20) zwei Polypropylenschaumfolien (XPP-Folien) (1, 2) auf eine Temperatur zwischen 150°C und 210°C erwärmt.As shown schematically in FIG. 1, two polypropylene foam films (XPP films) (1, 2) are heated to a temperature between 150 ° C. and 210 ° C. in an infrared heating device (10, 20).
Die erwärmten Schaumstoffolien (1, 2) werden in ein poröses Umform- werkzeug (Figur 2) mit den beiden temperierbaren Werkzeughälften (5, 6) aus handelsüblichem Porenharz der Marke Metapor® transferiert und durch Anlegen eines Unterdrucks (symbolisiert durch die Pfeile 3, 4) an den porösenThe heated foam sheets (1, 2) are transferred to a porous forming tool (FIG. 2) with the two mold halves (5, 6) made of commercially available pore resin of the Metapor ® brand and by applying a vacuum (symbolized by the arrows 3, 4 ) on the porous
Werkzeughälften (5, 6) fixiert.Tool halves (5, 6) fixed.
Durch Regulierung des Unterdrucks (Figur 3) an den beiden Werkzeughälften (5, 6) wird eine beginnende Umformung der Schaumstoffolien (1, 2) und Anpassung an die Innenkontur der Werkzeughälften (5, 6) erreicht.By regulating the negative pressure (Figure 3) on the two tool halves (5, 6), an initial deformation of the foam sheets (1, 2) and adaptation to the inner contour of the tool halves (5, 6) is achieved.
Während des Schließvorgangs der Werkzeughälften (5, 6) (Figur 4) wird eine vollständige Umformung der Schaumstoffolien (1, 2) und Anpassung an die Innenkontur der Werkzeughälften (5, 6) erreicht. Durch Schließen der Werkzeughälften (5, 6) (Figur 5) und Anlegen äußerenDuring the closing process of the tool halves (5, 6) (FIG. 4), the foam foils (1, 2) are completely reshaped and adapted to the inner contour of the tool halves (5, 6). By closing the tool halves (5, 6) (Figure 5) and putting on the outer
Drucks (symbolisiert durch die Pfeile 7) und ggf. Wärmezufuhr wird einePressure (symbolized by the arrows 7) and, if applicable, heat supply becomes a
Verbindung der Schaumstoffolien (1, 2) an der Trennebene (8) erreicht. DerConnection of the foam sheets (1, 2) reached at the parting plane (8). The
Unterdruck an den Werkzeughälften (5, 6) wird zumindest teilweise aufrecht- erhalten, um ein Verziehen der Folien zu vermeiden.Vacuum on the tool halves (5, 6) is at least partially maintained in order to avoid warping of the foils.
Die Werkzeughälften (5, 6) werden nach Aufhebung des Unterdrucks geöffnet (Figur 6), wonach das aus den Schaumstoffolien (1, 2) gefertigte Formteil (30), ein Hohlkörper aus geschäumtem Polypropylen, entnommen wird. The tool halves (5, 6) are opened after the negative pressure has been released (FIG. 6), after which the molded part (30), a hollow body made of foamed polypropylene, is made from the foam foils (1, 2).

Claims

Patentansprüche claims
1. Verfahren zur Herstellung geschäumter Kunststoffhohlkörper, dadurch gekennzeichnet, daß mindestens zwei Halbzeuge aus geschäumtem, thermo- plastischem Kunststoff über poröse oder perforierte Werkzeughälften, an denen jeweils Unterdruck anliegt, umgeformt werden und über Druck und/oder Temperatur zu einem Hohlkörper stoffschlüssig verbunden werden.1. A process for the production of foamed plastic hollow bodies, characterized in that at least two semi-finished products made of foamed, thermoplastic plastic over porous or perforated mold halves, each of which is under vacuum, are formed and cohesively connected to a hollow body via pressure and / or temperature.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß als Halbzeuge ein- oder mehrlagige, unvernetzte Polypropylenschaumfolien (XPP-Folien) verwendet werden.2. The method according to claim 1, characterized in that single or multi-layer, uncrosslinked polypropylene foam films (XPP films) are used as semi-finished products.
3., Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, daß als Halbzeuge geschäumte, thermoplastische Kunststoffolien in Kombination mit ungeschäumten Kunststoffolien, Geweben, Gewirken, Nonwovens, Glasfasern oder Dekor- und Deckschichten verwendet werden.3., Method according to claim 1 or 2, characterized in that foamed, thermoplastic plastic films are used as semi-finished products in combination with non-foamed plastic films, woven fabrics, knitted fabrics, nonwovens, glass fibers or decorative and cover layers.
4. Verfahren nach Anspruch 3, dadurch gekennzeichnet, daß als Halbzeuge unvernetzte Polypropylenschaumfolien mit aufkaschierten oder koextrudierten ungeschäumten Folien eingesetzt werden.4. The method according to claim 3, characterized in that non-crosslinked polypropylene foam films with laminated or coextruded non-foamed films are used as semi-finished products.
5. Verfahren nach Anspruch 3 oder 4, dadurch gekennzeichnet, daß die unvernetzte Polypropylenschaumfolie zumindest teilweise mit aufkaschierten Dekorschichten, insbesondere Dekorfolien oder textilen Schichten, verbunden ist.5. The method according to claim 3 or 4, characterized in that the uncrosslinked polypropylene foam film is at least partially connected to laminated decorative layers, in particular decorative films or textile layers.
6. Verfahren nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, daß Einlegeteile oder Dekorelemente wie beschriftete Folien während des Prozesses angeformt werden.6. The method according to any one of claims 1 to 5, characterized in that inserts or decorative elements such as labeled foils are molded during the process.
7. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, daß die Werkzeughälften aus einem porösen oder perforierten Harz, porösen oder perforierten Metall, einem Metallgitter, Sintermetall oder Kombinationen daraus bestehen.7. The method according to any one of claims 1 to 6, characterized in that the tool halves made of a porous or perforated resin, porous or perforated metal, a metal grid, sintered metal or combinations thereof.
8. Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, daß Werkzeughälften verwendet werden, deren Oberfläche mindestens teilweise strukturiert ist.8. The method according to any one of claims 1 to 7, characterized in that tool halves are used, the surface of which is at least partially structured.
9. Verfahren nach Anspruch 8, dadurch gekennzeichnet, daß die strukturierte Oberfläche eine Narbung oder eine Textilstruktur aufweist.9. The method according to claim 8, characterized in that the structured surface has a grain or a textile structure.
10. Verfahren nach einem der Ansprüche 1 bis 9, dadurch gekennzeichnet, daß die umzuformenden Halbzeuge vor dem Umformprozeß und/oder während des Umformprozesses erwärmt werden.10. The method according to any one of claims 1 to 9, characterized in that the semi-finished products to be formed are heated before the forming process and / or during the forming process.
11. Verfahren nach Anspruch 10, dadurch gekennzeichnet, daß die umzuformenden Halbzeuge über Infrarotstrahlung erwärmt werden.11. The method according to claim 10, characterized in that the semi-finished products to be formed are heated by infrared radiation.
12. Verfahren nach Anspruch 10 oder 11, dadurch gekennzeichnet, daß die umzuformenden Halbzeuge auf eine Temperatur von 150 - 250°C erwärmt werden.12. The method according to claim 10 or 11, characterized in that the semi-finished products to be formed are heated to a temperature of 150 - 250 ° C.
13. Verfahren nach einem der Ansprüche 1 bis 12, dadurch gekennzeichnet, daß die Werkzeughälften temperiert werden.13. The method according to any one of claims 1 to 12, characterized in that the tool halves are tempered.
14. Verfahren nach einem der Ansprüche 1 bis 13, dadurch gekennzeichnet, daß der an die Werkzeughälften angelegte Unterdruck während des Umform- Vorganges regulierbar ist.14. The method according to any one of claims 1 to 13, characterized in that the negative pressure applied to the mold halves is adjustable during the forming process.
15. Verfahren nach einem der Ansprüche 1 bis 14, dadurch gekennzeichnet, daß über eine Lanze ein Überdruck im entstehenden Hohlraum des Hohlkörpers erzeugt wird.15. The method according to any one of claims 1 to 14, characterized in that an overpressure is generated in the resulting cavity of the hollow body via a lance.
16. Verfahren nach einem der Ansprüche 1 bis 14, dadurch gekennzeichnet, daß über eine Lanze ein Unterdruck im entstehenden Hohlraum des Hohlkörpers erzeugt wird. 16. The method according to any one of claims 1 to 14, characterized in that a negative pressure is generated in the resulting cavity of the hollow body via a lance.
17. Verfahren nach einem der Ansprüche 1 bis 16, dadurch gekennzeichnet, daß die umgeformten Kunststoffhalbzeuge an der Trennebene der Werkzeughälften miteinander verbunden werden.17. The method according to any one of claims 1 to 16, characterized in that the formed semi-finished plastic products are connected to one another at the parting plane of the tool halves.
18. Verfahren nach Anspruch 17, dadurch gekennzeichnet, daß die umgeformten Kunststoffhalbzeuge an der Trennebene der Werkzeughälften unter18. The method according to claim 17, characterized in that the formed plastic semi-finished products at the parting plane of the tool halves
Einsatz von Druck und/oder Temperatur miteinander verschweißt werden.Use of pressure and / or temperature to be welded together.
19. Kunststoffhohlkörper, hergestellt nach dem Verfahren gemäß einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß es sich um einen Isolierbehälter handelt.19. Plastic hollow body, produced by the method according to any one of the preceding claims, characterized in that it is an insulated container.
20. Kunststoffhohlkörper, hergestellt nach dem Verfahren gemäß einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß es sich um ein Teil einer Kraftfahrzeugirmenausstattung, beispielsweise ein Luftführungselement, handelt. 20. Plastic hollow body, produced by the method according to any one of the preceding claims, characterized in that it is part of a motor vehicle company equipment, for example an air guiding element.
PCT/EP2004/003173 2003-03-25 2004-03-25 Plastic hollow bodies and method for the production thereof WO2004094130A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10313495A DE10313495A1 (en) 2003-03-25 2003-03-25 Forming plastic hollow shapes, e.g. for air ducts, involves drawing pre-heated sheets to permeable tool walls by suction and then closing tool to seal edges
DE10313495.6 2003-03-25

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Publication Number Publication Date
WO2004094130A1 true WO2004094130A1 (en) 2004-11-04

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PCT/EP2004/003173 WO2004094130A1 (en) 2003-03-25 2004-03-25 Plastic hollow bodies and method for the production thereof

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DE102020134732A1 (en) 2020-12-22 2022-06-23 Liebherr-Hausgeräte Ochsenhausen GmbH thermoformed part

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