Method for the production of a molded part

• US 8,007,706 B2
• Filed: 03/27/2007
• Issued: 08/30/2011
• Est. Priority Date: 03/28/2006
• Status: Expired due to Fees

• Current Assignee: HBW-Gubesch Thermoforming GmbH (Gubesch GmbH)
• Original Assignee: Jacob Composite GmbH
• Inventors: Wacker, Marco, Russ, Joerg
• Primary Examiner(s): Michener; Jennifer K.
• Assistant Examiner(s): Slawski; Magali P
• Application Number:
  US11/728,796
• Publication Number:
  US 20070235900A1
• Time in Patent Office: 1,617 Days
• Field of Search: 264/255, 264/263, 264/274
• US Class Current: 264/322
• CPC Class Codes: B29C 43/146 for making multilayered articles
• CPC Class Codes: B29C 45/1418 the inserts being deformed or preformed, e.g. by the injection pressure
• CPC Class Codes: B29C 45/14786 Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
• CPC Class Codes: B29C 45/14811 Multilayered articles B29C45/14827 takes precedence
• CPC Class Codes: B29C 51/082 by shaping between complementary mould parts
• CPC Class Codes: B29C 51/10 Forming by pressure difference, e.g. vacuum
• CPC Class Codes: B29C 51/14 using multilayered preforms or sheets
• CPC Class Codes: B29K 2705/00 Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
• CPC Class Codes: B29K 2713/00 Use of textile products or fabrics for preformed parts, e.g. for inserts B29K2105/06 takes precedence
• CPC Class Codes: B29L 2009/001 the layers being loose
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• CPC Class Codes: Y10T 156/1002 with permanent bending or reshaping or surface deformation of self sustaining lamina

Abstract

The invention relates to a method for the production of a molded part which comprises a base part consisting of a plurality of layers and a thermoplastic or duroplastic synthetic material bonded therewith, the bond of the base part with the thermoplastic or duroplastic synthetic material being formed such that the thermoplastic or duroplastic synthetic material is deformed under a pressure to become flowable, or that it is introduced already liquefied under pressure and forms a bond with the base part. According to the invention, the production of the base part and the production of the bond of the thermoplastic or duroplastic synthetic material with the base part is carried out in the same die.

Claims

1. Method for the production of a molded part which comprises a base part having a plurality of layers and a thermoplastic or duroplastic synthetic material bonded therewith, comprising the steps of

firstly, inserting at least two layers of the base part into a die and deforming the same with a first stamp to create a connection between these layers,

subsequently, forming the bond of the base part with the thermoplastic or duroplastic synthetic material such that the thermoplastic or duroplastic synthetic material is deformed with a second separate stamp in the same die under a pressure to become flowable, or introduced already liquefied under pressure and forms a bond with the base part, and

carrying out the production of the base part and bonding of the thermoplastic or duroplastic synthetic material with the base part in the same die with said first and second separate stamps, wherein

in one method step, at least two layers of the base part are inserted into a die and deformed therein so that a connection is created between these layers, and in another method step, a thermoplastic or duroplastic synthetic material is inserted into the die already liquefied and then forming a bond with the base part.

2. Method according to claim 1, wherein

the production of the base part and bond between the base part and thermoplastic or duroplastic synthetic material is performed simultaneously or in succession.

3. Method according to claim 1, wherein the base part is a composite material.

4. Method according to claim 1, wherein at least one of the layers of the base part has a single-layer or multi-layer structure in turn.

5. Method according to claim 1, wherein at least one of the layers of the base part is formed by a composite material or by a thermoplastic or duroplastic material.

6. Method according to claim 1, wherein the base part comprises at least one layer which has a cellular or honeycomb structure.

7. Method according to claim 1, wherein one layer, a plurality of layers, or all layers of the base part are preheated in the die, prior to deforming.

8. Method according to claim 7, wherein preheating is achieved through the effect of IR radiation, microwaves, laser or hot air, or a combination thereof on the layers of the base part.

9. Method according to claim 1, whereinthe base part is produced by the twin-sheet molding method.

10. Method according to claim 1, wherein the base part is produced by a vacuum forming method.

11. Method according to claim 1, wherein pressure is applied between two layers of the base part during its production.

12. Method according to claim 1, wherein a foam is introduced between two layers of the base part during or after its production.

13. Method according to claim 1, wherein the base part is produced by a matched-die molding method.

14. Method according to claim 1, wherein one layer, a plurality of layers, or all layers of the base part are fixed in position in one frame or a plurality of frames upon introduction into the die.

15. Method according to claim 1, wherein one layer, a plurality of layers, or all layers of the base part are placed, upon introduction into the die, onto a fabric structure or on a plurality of strands.

16. Method according to claim 15, wherein the fabric structure or the strands are composed of glass fibers, metal fibers or synthetic fibers.

17. Method according to claim 15, wherein the fabric structure or the strands are or will be pretreated for the purpose of improving adhesion.

18. Method according to claim 15, wherein the fabric structure or the strands are or will be produced according to the commingling method.

19. Method according to claim 1, wherein before or upon introduction into the die, one layer, a plurality of layers, or all layers of the base part are fixed by needles and transported.

20. Method according to claim 1, wherein the base part is a composite material which comprises at least one layer which has a cellular or honeycomb structure and this layer is deformed with other layers of the composite component at a pressure of 50 bar maximum.

21. Method according to claim 1, wherein the thermoplastic or duroplastic synthetic material is deformed at a pressure of 250 bar maximum.

22. Method according to claim 1, wherein the layers of the base part are composed of polyamide, polybutylene terephthalate, polyethylene or polypropylene or high-temperature thermoplastics or thermoplastic elastomers (TPEs).

23. Method according to claim 1, wherein the layers of the base part are reinforced by glass fibers, carbon fibers, natural fibers, aramide fibers, metallic fibers and/or synthetic fibers.

24. Method according to claim 1, wherein the layers of the base part comprise inherently reinforced polymers.

25. Method according to claim 1, wherein the base part is a composite material which comprises at least one layer which has a cellular or honeycomb structure, with this layer composed of paper, cardboard or metal.

26. Method according to claim 1, wherein the plurality of layers of the base part is deformed by the die such that the separation between the stamps of the die is covered by the layers of the base part and no thermoplastic or duroplastic synthetic material can flow into the base part.

27. Method according to claim 1, wherein one layer, a plurality of layers, or all layers of the base part comprise at least a holding area in which the layers are fixed by frames or another holding device, with the holding areas being charged such that they are reformed with the thermoplastic or duroplastic synthetic material.

28. Method according to claim 27, wherein the holding area or the holding areas have at least one opening or into which the thermoplastic or duroplastic synthetic material penetrates for the purpose of producing a form-fitting bond.

29. Method according to claim 15, wherein the strands are fiber strands.

30. Method according to claim 16, wherein the synthetic fibers are PTFE.

31. Method according to claim 20, wherein the pressure is from 20 bar to 30 bar.

32. Method according to claim 22, wherein the high-temperature thermoplastics are PPS (polyphenylene sulfide) or PEI (polyetherimide).

33. Method according to claim 25, wherein the metal is aluminum.

34. Method according to claim 20, wherein the thermoplastic or duroplastic material is deformed at a pressure of 250 bar maximum.

35. Method according to claim 1, wherein the first stamp operates at a pressure up to about 30 bar, and the second stamp operates at a pressure of about 200 to 250 bar.

36. Method according to claim 1, wherein the thermoplastic or duroplastic synthetic material is already liquefied under pressure when inserted into the die.