Device and method for producing molded parts

Abstract

The invention relates to a device for producing a molded part (1), in particular made of a fibre composite material. The aim of the invention is to provide a uniform pressurization and / or application temperature even if the molded part has a complex geometry. The second moulding section (P2, P2 ') is at least partially spaced apart from the first moulding section (2) in the direction of the movement axis (B), and at least one shape curvature of the second moulding section (P2, P2') is designed, in particular along a longitudinal extension and / or a transverse extension of the respective moulding tool (2, 3), the second molded section (P2, P2 ') is at least partially different from at least one shape curvature of the first molded section (P1, P1'), preferably from an edge region of the first molded section (P1, P1 ') adjoining the second molded section (P2, P2'). The invention also relates to a method for producing a molded part, in particular made of a fiber composite material, comprising in particular a corresponding device for producing a molded part (1), in particular made of a fiber composite material.

Description

Technical Field

[0001] The present invention relates to a device for manufacturing molded parts, in particular molded parts made of fiber composite materials, comprising: a first molding tool, a second molding tool, and at least one diaphragm that is at least partially elastically deformable and is used to contact a workpiece, wherein the first molding tool and the second molding tool are capable of moving relative to each other along a movement axis between an open position and a closed position, wherein a chamber for a working medium is constructed between the diaphragm and the first molding tool and / or the second molding tool, at least in the closed position, wherein a working space for accommodating the workpiece is constructed between the first molding tool and the second molding tool, wherein the surface of the first molding tool and / or the surface of the second molding tool has a first molding section and a second molding section, wherein the first molding section and the second molding section are adjacent to the working space and / or the chamber, and wherein the diaphragm is made of metal.

[0002] Furthermore, the present invention relates to a method for producing a molded part, in particular a molded part made of a fiber composite material, comprising the following steps: a) providing a workpiece, b) providing an apparatus for producing a molded part according to any one of claims 1 to 14, and c) applying pressure and / or applying temperature to the workpiece by means of the apparatus for producing a molded part. Background Art

[0003] Fiber composites are composite materials that essentially consist of two main components: reinforcing fibers and the plastic ("matrix" or "resin") in which the fibers are embedded. The combination of these two main components allows the composite material to have overall better properties than either component considered separately. For example, fibers contribute to the tensile strength of the composite material due to their high tensile strength along the fiber direction. Conversely, the matrix is responsible for, for example, holding the fibers in place and protecting them from mechanical and chemical influences.

[0004] One of the many possibilities for producing molded parts from fiber composite materials is based on the use of prefabricated fiber-resin semifinished products (so-called "prepregs," short for "pre-impregnated fibers"). In these semifinished products, the fibers are provided with a resin system that has not yet fully reacted, resulting in a flexible form (e.g., in the form of a strip on a roll). The prepreg is not deformed until the molded part is produced and hardens under high pressure and temperature by completing the chemical reaction. This step can be performed, for example, in a press.

[0005] Prepregs are processed in large quantities, for example, in the aviation industry. The challenge in processing these molded parts is that they often require very complex geometries, for example due to reinforcement elements such as stringers. Furthermore, the assembly burden should be reduced by using fewer, but therefore larger, molded parts. The complex geometries combined with the large dimensions of the molded parts place high demands on the equipment and methods used to manufacture these molded parts.

[0006] For example, DE 10 2017 113 595 A1 discloses an apparatus and method for producing molded parts made of fiber composite materials. Uniform pressure is applied to the molded part to be produced by an elastic diaphragm acting on the workpiece (from which the molded part is formed), with oil pressure acting on the diaphragm from the side facing away from the workpiece. The diaphragm is thus pressed against the workpiece surface by the oil pressure, thereby assuming the shape of the workpiece. This ensures that the oil pressure acts on all sides, even in the case of curved workpiece or molded part surfaces, and that the force exerted by the diaphragm on the workpiece surface is uniform at all locations, particularly the force components acting orthogonally to the workpiece surface. However, a major disadvantage is that the curvature of the shape of the molding tool is constant across the surface of the molding tool. Molded parts with complex geometries, particularly those with varying and / or opposing curvatures, cannot be produced, or can only be produced with great difficulty, using this apparatus.

[0007] US 2016 / 0 297 153 A1 also discloses the use of such a "diaphragm press" for producing molded parts made of fiber composite materials. However, its main disadvantage is that only a rigid wall is provided for contact with the workpiece or molded part. While the rigid wall can be connected to a flexible diaphragm, the flexible diaphragm is not designed for contact with the workpiece. In particular, in areas of workpieces or molded parts with relatively complex geometries, such a rigid wall cannot or is not sufficiently strong enough to adapt to the geometry of the workpiece or molded part through elastic deformation, thus preventing uniform pressure and / or temperature application. Summary of the Invention

[0008] The object of the present invention is therefore to provide a device and a method for producing molded parts, in particular made of fiber composite materials, which provide for uniform pressure application and / or temperature application even in the case of molded parts with more complex geometries.

[0009] This object is achieved in the apparatus according to the preamble of claim 1 by providing that the second embossing section is at least partially spaced apart from the first embossing section in the direction of the axis of movement, and that at least one curvature of the second embossing section is designed to differ, in particular along the longitudinal extension and / or transverse extension of the respective embossing tool, at least partially from at least one curvature of the first embossing section, preferably from the curvature of the edge region of the first embossing section adjacent to the second embossing section. This provides a geometry of the embossing tool or tools that is particularly well adapted to workpieces or molded parts with complex geometries. If the respective embossing tool is, for example, designed to contact the workpiece, the embossing tool or tools can be provided with a shape adapted to the workpiece. This provides uniform contact between the workpiece and the embossing tool, which facilitates uniform application of pressure and / or temperature. If, for example, a cavity is formed between the respective embossing tool, including the embossing section, and the membrane, such a cavity can be provided that has a substantially constant thickness, particularly in the closed position. The shape of the respective embossing tool can thus be adapted by the shape of the embossing section so that, at least when the workpiece is pressurized and / or heated, the shape of the embossing section corresponds to the shape of the membrane and / or workpiece.

[0010] In particular, at least one shape curvature of the second stamped section can differ in value and / or sign from at least one shape curvature of the first stamped section. Thus, the second stamped section has a curvature change relative to the first stamped section, so that the second stamped section and the first stamped section extend at least partially in different directions.

[0011] Here, the shape of the embossed section describes the general shape of the individual sections. Structural deviations, as described in DIN 4760:1982-06, preferably at least 2nd and / or 3rd and higher order, are not considered part of the shape, nor are they considered part of the curvature of the form. 2nd order structural deviations are waviness, and 3rd to 5th order structural deviations are roughness. Therefore, curvature of form does not refer to defects, especially surface defects, of the embossing tool, in particular the embossed section.

[0012] In particular, at least one shape curvature of the second molded section is at least partially larger or smaller than at least one shape curvature of the first molded section, preferably at least 1.05 times, preferably at least 1.25 times, more preferably at least 2 times, more preferably at least 4 times, more preferably at least 10 times, more preferably at least 25 times, more preferably at least 50 times, more preferably at least 100 times, more preferably at least 250 times, more preferably at least 500 times, more preferably at least 1000 times, more preferably at least 2500 times, more preferably at least 5000 times, and in particular at least 10000 times.

[0013] The apparatus comprises a first, preferably upper, pressing tool and a second, preferably lower, pressing tool, although it may also comprise other pressing tools. The first and / or second pressing tools may be constructed in one piece or in multiple pieces. The first and / or second pressing tools are preferably made of metal, in particular high-nickel steel, high-nickel cast iron, or high-nickel cast steel. The nickel content of each may be greater than 34%, preferably between 35.7% and 36.7%, or between 40.8% and 43.6%. The use of metal, in particular steel, ensures a long service life for the pressing tools. Steel, such as Invar 36, also has a very low coefficient of thermal expansion. Therefore, the use of Invar allows for highly precise production of molded parts even when temperature fluctuations occur during the pressing process. Further advantages can be achieved by specially adapted casting alloys, preferably high-nickel cast iron or high-nickel cast steel, with which not only the maximum coefficient of thermal expansion can be kept low, but also the requirements of the workpiece material, for example, thermosetting materials (reinforced with glass fibers or carbon fibers) or thermoplastic materials (reinforced with glass fibers or carbon fibers), can be largely adapted during the majority of the heating and cooling processes in the molding cycle. Furthermore, the use of cast materials offers significant economic advantages, since high-nickel alloy steels are very expensive, and the stock removal rates during machining processes in structural forming have so far typically been well over 50%, often even exceeding 70% or 80%.

[0014] Here, the first and second molding tools are movable relative to each other along an axis of motion between an open position and a closed position. This allows the molding tools to be moved toward or away from a workpiece placed in the press or a molded part to be produced from the workpiece. In the open position, the workpiece can be placed between the molding tools, or the finished molded part can be removed from between the two molding tools. In the closed position, the workpiece can be pressurized and / or heated to produce the molded part. The axis of motion also defines the defined movement of the molding tools. The axis of motion is the axis along which the molding tools move relative to each other between the open and closed positions. Advantageously, the axis of motion runs horizontally or vertically. Alternatively or additionally, the axis of motion extends through the first and / or second molding tools, in particular, substantially centrally therethrough. Alternatively or additionally, the axis of motion extends through the workspace and / or chamber, in particular, substantially centrally therethrough. In addition, the movement axis can be directed from the first pressing tool to the second pressing tool, or vice versa.In addition, the movement axis can be directed parallel to a vertical axis of the first pressing tool and / or the second pressing tool, in particular a vertical axis of the device.

[0015] Furthermore, the first embossing tool and / or the second embossing tool can advantageously have at least partially a constant thickness at least adjacent to the working space and / or the cavity, in particular in the direction of the movement axis.

[0016] The device also includes at least one at least partially elastically deformable diaphragm for contacting the workpiece. Since the diaphragm is at least partially elastically deformable, it can be adapted to the geometry of the workpiece or the molded part to be manufactured. In this case, the diaphragm can advantageously be at least partially linearly elastically deformable. In addition, the diaphragm is advantageously configured to contact the molded part to be manufactured and / or to apply pressure and / or temperature to the workpiece. Advantageously, the diaphragm is at least partially movable in the direction of the workspace, the chamber, the first molding tool and / or the second molding tool, preferably in an extendable manner, further preferably in an elastically deformable manner, in particular in a linearly elastic manner. In addition, the diaphragm can be essentially fully elastically deformable, in particular linearly elastically deformable. However, in the case of a workpiece or molded part to be manufactured having a complex geometry, it is advantageous if a portion of the diaphragm is plastically pre-deformed and thereby adapted to the shape of the workpiece or the molded part to be manufactured before the workpiece is pressurized and / or heated.

[0017] Furthermore, the diaphragm is currently made of metal. This provides a sufficiently stable diaphragm that can withstand high pressures and / or temperatures and inherently has high thermal conductivity. Furthermore, the metal diaphragm can be deformed both elastically and plastically, in particular, it can be plastically pre-deformed. A special feature of the current device is that the metal diaphragm is used in conjunction with a first embossing section and a second embossing section, wherein the second embossing section is at least partially spaced apart from the first embossing section along the axis of motion, and at least one curvature of the second embossing section is designed to differ at least partially from at least one curvature of the first embossing section, preferably from the curvature of the edge region of the first embossing section adjacent to the second embossing section. In embossing tools with such complex geometries and / or workpieces with complex geometries, diaphragms made of metal can only be used to a limited extent or not at all. While metal diaphragms can indeed deform elastically to a certain extent, their elastic deformation capacity, in particular linear elastic deformation capacity, is relatively low compared to diaphragms made of other materials, such as silicone. Therefore, a diaphragm made of metal can only adapt to the geometry of the molding tool and / or the workpiece to a certain extent through elastic deformation. However, this disadvantage can be compensated, for example, by plastically pre-deforming the diaphragm's forming section. A diaphragm made of metal has the advantage over, for example, a diaphragm made of silicone that it can withstand higher pressures and / or temperatures than a diaphragm made of silicone.

[0018] The diaphragm is preferably constructed in one piece and / or in one piece, in particular made of sheet metal. Advantageously, the diaphragm thickness is at least 0.05 mm, preferably at least 0.2 mm, and in particular at least 0.25 mm. This ensures sufficient diaphragm strength. Alternatively or additionally, the diaphragm thickness is a maximum of 4 mm, preferably a maximum of 2 mm, and in particular a maximum of 1.5 mm. This ensures sufficient diaphragm flexibility.

[0019] The diaphragm can preferably be made of steel, in particular stainless steel. In simple cases, it is sufficient to use stainless steel with the material grade 1.4301 for the diaphragm. However, preferably, the diaphragm should be made of a steel with good to excellent deep-drawing properties, in particular stainless steel, so-called deep-drawing steel.

[0020] The membrane can advantageously have a tensile strength of 300 MPa to 850 MPa, in particular 310 MPa to 540 MPa or 490 MPa to 830 MPa. The membrane can in particular be made of steel containing at least the following weight percentages of elements or compounds:

[0021] - Carbon: in the range of about 0.16% to 0.22%,

[0022] -Silicon: about 0.13%,

[0023] - Manganese: in the range of about 0.2% to 0.4%,

[0024] - Nickel: to about 0.25%,

[0025] - Sulfur: to about 0.025%,

[0026] - Phosphorus: to about 0.025%,

[0027] - Chromium: to about 0.15%,

[0028] - Aluminum: in the range of about 0.02% to 0.07%,

[0029] - Copper: about 0.2%,

[0030] The remainder is iron and unavoidable impurities. The membrane can be produced, for example, from a heat-annealed steel strip or a hot-rolled steel strip according to GOST 2284-79.

[0031] Other steel alloys containing chromium, nickel and advantageously also titanium and / or copper may also achieve good results.

[0032] Advantageously, the diaphragm is at least partially arranged between the first and second molding tools. Furthermore, the first and / or second molding tools may be connected to the diaphragm. The apparatus may also include two or at least two diaphragms. By using two or at least two diaphragms, pressure and / or temperature can be easily transferred to the workpiece from different sides.

[0033] A chamber for the working medium is formed between the diaphragm and the first and / or second molding tools, at least in the closed position. Furthermore, a chamber can be formed between the diaphragm and the first and / or second molding tools in both the open and closed positions, preferably in each position of the molding tools. The chamber is preferably at least partially defined by the diaphragm and the first and / or second molding tools. The chamber advantageously has a substantially uniform thickness, particularly along the longitudinal and / or transverse extension of the diaphragm, at substantially every position between the diaphragm and the first and / or second molding tools. In other words, the chamber has a substantially constant thickness, at least in the closed position. The chamber can be filled with the working medium. The working medium can be, for example, a gas or a liquid. Furthermore, the working medium can preferably be pressurized and / or heated. The pressure and / or temperature that can be applied to the working medium can be transmitted to the workpiece via the diaphragm. Furthermore, the chamber advantageously extends toward the workspace. The chamber can be subjected to an oil pressure of at least 0.1 bar, preferably at least 2 bar, even more preferably at least 6 bar, in particular at least 8 bar, and / or up to 40 bar, preferably up to 26 bar, in particular up to 22 bar. Furthermore, the chamber is preferably sealed against an oil pressure of at least 4 bar, preferably at least 8 bar, in particular at least 40 bar, by the first and / or second molding tools and the diaphragm.

[0034] Furthermore, a working space for accommodating a workpiece is formed between the first and second molding tools, in particular between the membrane and the first and / or second molding tools. The working space is preferably configured at least in an open position and / or at least in a closed position, in particular in every position of the molding tools. The workpiece can then be placed in the working space in the open position, and in the closed position, pressurized and / or heated, in particular by means of the membrane.

[0035] Here, the surface of the first molding tool and / or the surface of the second molding tool have a first molding section and a second molding section. Thus, both the surface of the first molding tool and the surface of the second molding tool may have a first molding section and a second molding section. However, the surface of the first molding tool and / or the surface of the second molding tool may also have additional molding sections. Furthermore, the first molding section and the second molding section preferably abut each other, particularly along the longitudinal extension and / or transverse extension of the respective molding tool.

[0036] The first and second die sections currently adjoin the workspace and / or cavity. These die sections thus form sections of the die tool that are intended to come into contact with the workpiece and / or to form the cavity shape. In this case, the first and second die sections adjoin the workspace and / or cavity, particularly at least in the closed position, preferably at least in the closed and open positions. Furthermore, the first and / or second die sections preferably point at least partially, preferably substantially completely, toward the workspace and / or cavity, particularly at least in the closed position.

[0037] The first and / or second embossing sections are preferably also designed to contact a workpiece. Thus, these embossing sections each form a contact surface for the workpiece. Due to this design of the embossing sections, the embossing tool is also suitable for accommodating workpieces with complex geometries. The first and / or second embossing sections can extend at least partially, preferably substantially completely, in a straight line and / or can extend at least partially, preferably substantially completely, in a curved line.

[0038] The longitudinal extension of the respective molding tool is the extension of the respective molding tool, in particular starting from the lateral side of the respective molding tool along the longitudinal axis of the respective molding tool. The transverse extension of the respective molding tool is the extension of the respective molding tool, in particular starting from the longitudinal side of the respective molding tool along the transverse axis of the respective molding tool. In this case, the transverse extension of the respective molding tool does not necessarily have to run only in the direction of the transverse axis of the respective molding tool, or may not run at all in some cases. If, for example, the respective molding tool extends at least partially in the shape of a circular arc around the longitudinal axis of the respective molding tool, then the transverse extension of the respective molding tool also runs partially in the direction of the transverse axis of the respective molding tool and partially in the direction of the vertical axis of the respective molding tool. This also applies to the longitudinal extension of the respective molding tool. The longitudinal axis of the respective molding tool and the transverse axis of the respective molding tool are perpendicular to each other.

[0039] A first embodiment of the apparatus is characterized in that the second embossing section is at least partially spaced apart from the first embossing section in the direction of the movement axis by a spacing of at least 5 mm, preferably at least 50 mm, more preferably at least 150 mm, more preferably at least 200 mm, more preferably at least 300 mm, more preferably at least 500 mm, and in particular at least 1000 mm. This spacing simplifies the uniform application of pressure and / or temperature to workpieces with complex geometries, as the embossing section better adapts to the geometry of such workpieces or, at least, provides a chamber with a more uniform thickness when the workpiece is pressurized and / or heated. Alternatively or additionally, the spacing can correspond to at least 1.25 times, preferably at least 1.41 times, more preferably at least 7 times, more preferably at least 25 times, more preferably at least 50 times, and in particular at least 100 times the thickness of the membrane.

[0040] According to one design scheme of the device, at least one shape curvature of the second die section is designed to be, in particular, along the longitudinal extension and / or lateral extension of the corresponding die tool, at least partially opposite to at least one shape curvature of the first die section, preferably opposite to the shape curvature of the edge area of the first die section adjacent to the second die section. This provides a die tool shape that matches the geometry of the workpiece or the molded part to be manufactured. As a result, the die section can contact the workpiece more evenly, or at least provide a cavity with a more uniform thickness when the workpiece is pressurized and / or heated. Opposite curvatures are currently understood to mean that these curvatures have different signs. For example, the first die section can bend to the left, so the sign is positive, and the second die section can bend to the right, so the sign is negative, or it can be unbent, in which case the curvature is zero and the curvature has no sign. Positive sign, negative sign and no sign are respectively regarded as different signs here.

[0041] Another embodiment of the apparatus is characterized in that the second embossing section extends at least partially obliquely relative to the first embossing section, in particular along the longitudinal extension and / or transverse extension of the respective embossing tool. Preferably, an angle of at least 90°, preferably at least 100°, in particular at least 120°, and / or a maximum of 180°, preferably a maximum of 160°, in particular a maximum of 145°, exists at least partially between the first embossing section and the second embossing section. This provides a embossing tool shape that is adapted to the geometry of the workpiece or molded part to be produced. Consequently, the embossing section can contact the workpiece more uniformly or, at least when pressurized and / or heated, provide a cavity with a more uniform thickness.

[0042] According to another embodiment of the apparatus, the surface of the first embossing tool and / or the surface of the second embossing tool comprises a third embossing section, and preferably, the third embossing section is at least partially spaced apart from the first embossing section and / or the second embossing section along the axis of motion. Furthermore, the third embossing section is preferably spaced apart from the first embossing section and / or the second embossing section along the axis of motion by a spacing of at least 5 mm, preferably at least 50 mm, more preferably at least 150 mm, more preferably at least 200 mm, more preferably at least 300 mm, more preferably at least 500 mm, and in particular at least 1000 mm. The provision of the third embossing section allows for a more compact shape of the embossing tool and, therefore, better adaptability to the geometry of complex components. The corresponding spacing simplifies uniform pressurization and / or temperature application in workpieces with complex geometries, as the embossing section better adapts to the geometry of the workpiece or, at least, provides a cavity with a more uniform thickness when pressurizing and / or heating the workpiece. Alternatively or additionally, the spacing can be at least 1.25 times, preferably at least 1.41 times, further preferably at least 7 times, further preferably at least 25 times, further preferably at least 50 times, and in particular at least 100 times the thickness of the diaphragm. The third molded section is adjacent to the working space and / or the chamber. In addition, the third molded section is preferably adjacent to the second molded section. Advantageously, it can be provided that the third molded section, in particular at least in the closed position, is at least partially, preferably substantially completely, pointed in the direction of the working space and / or the chamber. The third molded section can also be constructed for contact with the workpiece. Thus, the third molded section forms a contact surface for the workpiece. In addition, the third molded section can extend at least partially, preferably substantially completely, in a straight line and / or can extend at least partially, preferably substantially completely, in a curved manner.

[0043] Alternatively or additionally, the first molding section, the second molding section and / or the third molding section can have a length, in particular along the longitudinal extension and / or transverse extension of the corresponding molding tool, of at least 6 mm, preferably at least 50 mm, further preferably at least 70 mm, further preferably at least 100 mm, further preferably at least 150 mm, further preferably at least 500 mm, and in particular at least 1000 mm.

[0044] Another design of the apparatus provides that at least one shape curvature of the third die section is designed to differ at least partially from at least one shape curvature of the first die section, in particular along the longitudinal extension and / or transverse extension of the corresponding die tool, and / or at least one shape curvature of the third die section is designed to differ at least partially from at least one shape curvature of the second die section, preferably from the shape curvature of an edge region of the second die section adjacent to the third die section. This provides a die tool shape that matches the geometry of the workpiece or molded part to be manufactured. Consequently, the die sections can contact the workpiece more evenly, or at least provide a cavity with a more uniform thickness when pressurized and / or heated. This is particularly applicable to workpieces whose surfaces of adjacent die sections are curved and / or run obliquely relative to one another. In particular, at least one shape curvature of the third die section can differ in value and / or sign from at least one shape curvature of the first and / or second die sections. Thus, the third embossed section has a curvature variation relative to the first embossed section and / or the second embossed section, such that the third embossed section and the first embossed section and / or the second embossed section extend at least partially in different directions. Preferably, at least one shape curvature of the third embossed section is at least partially smaller or larger than at least one shape curvature of the first embossed section and / or the second embossed section, preferably than the shape curvature of an edge region of the second embossed section adjacent to the third embossed section, by a factor of at least 1.05, preferably at least 1.25, further preferably at least 2, further preferably at least 4, further preferably at least 10, further preferably at least 25, further preferably at least 50, further preferably at least 100, further preferably at least 250, further preferably at least 500, further preferably at least 1000, further preferably at least 2500, further preferably at least 5000, further preferably at least 10000, further preferably at least 2500, further preferably at least 5000, in particular at least 10,000.

[0045] It can also be provided that the third embossing section and the first embossing section and / or the second embossing section have essentially the same curvature and / or extend essentially parallel to one another.

[0046] According to another embodiment of the apparatus, at least one curvature of the third embossing section is designed to be at least partially opposite to at least one curvature of the first embossing section, particularly along the longitudinal extension and / or transverse extension of the respective embossing tool, and / or at least one curvature of the third embossing section is designed to be at least partially opposite to at least one curvature of the second embossing section, particularly along the longitudinal extension and / or transverse extension of the respective embossing tool, preferably opposite to the curvature of the edge region of the second embossing section adjacent to the third embossing section. This provides a embossing tool shape that is adapted to the geometry of the workpiece or molded part to be produced. Consequently, the embossing section can contact the workpiece more evenly, or at least provide a cavity with a more uniform thickness when the workpiece is pressurized and / or heated.

[0047] Another embodiment of the apparatus is characterized in that the third embossing section extends at least partially obliquely relative to the first and / or second embossing section, in particular along the longitudinal extension and / or transverse extension of the respective embossing tool. Preferably, an angle of at least 90°, preferably at least 100°, in particular at least 120°, and / or a maximum of 180°, preferably a maximum of 160°, in particular a maximum of 145°, is at least partially present between the third embossing section and the first and / or second embossing section. This provides a embossing tool shape that is adapted to the geometry of the workpiece or molded part to be produced. Consequently, the embossing sections can contact the workpiece more uniformly or, at least when the workpiece is pressurized and / or heated, provide a cavity with a more uniform thickness.

[0048] Another design of the apparatus provides that the first, second, and / or third molding sections, and in particular the shape of the first, second, and / or third molding sections, are at least partially curved about the longitudinal axis of the apparatus or an axis parallel to the longitudinal axis, about the transverse axis of the apparatus or an axis parallel to the transverse axis, and / or about the vertical axis of the apparatus or an axis parallel to the vertical axis. This allows for the provision of molding tools with complex geometries. Consequently, the molding sections can contact the workpiece more evenly, or at least provide a cavity with a more uniform thickness when pressurizing and / or heating the workpiece. This is particularly suitable for workpieces with complex geometries or molded parts to be manufactured. It is preferably provided that the first, second, and / or third embossing sections, in particular the shape of the first, second, and / or third embossing sections, are at least partially curved about at least two axes from the group of the longitudinal axes of the device, or about an axis parallel to the longitudinal axis of the device, about a transverse axis of the device or about an axis parallel to the transverse axis of the device, and about a vertical axis of the device or about an axis parallel to the vertical axis of the device. In other words, it is advantageous if the first, second, and / or third embossing sections, in particular the shape of the first, second, and / or third embossing sections, are at least partially curved about at least two axes running perpendicular to one another. This provides an at least partially doubly curved embossing tool. This allows for the simple production of molded parts with complex geometries, in particular doubly curved parts, or, in the case of molded parts with complex geometries, also provides cavities with more uniform thickness.

[0049] The longitudinal axis of the machine and the transverse axis of the machine are perpendicular to each other. The vertical axis is perpendicular to the longitudinal axis of the machine and perpendicular to the transverse axis of the machine. The corresponding axis of the machine is the axis of the machine used to produce the molded part.

[0050] According to another embodiment of the device, the diaphragm comprises, in particular along the longitudinal and / or transverse extension of the diaphragm, at least one elastically deformable base section for contacting the workpiece and at least one plastically pre-deformed shaped section for contacting the workpiece, and preferably, at least in the open position, the shaped section is plastically pre-deformed relative to the base section, in particular along the longitudinal and / or transverse extension of the diaphragm. The combination of the elastically deformable base section, which can be adapted very well to the particularly relatively uncomplicated geometry of the workpiece or the shaped part to be produced therefrom, and the plastically pre-deformed shaped section, which is adapted to the particularly complex geometry of the workpiece or the shaped part to be produced therefrom by plastic pre-deformation before the workpiece is pressurized and / or heated, allows particularly uniform pressurization and / or heating of geometries of varying complexity.

[0051] The longitudinal extension of a diaphragm is the extension of the diaphragm, in particular starting from a transverse side of the diaphragm along the longitudinal axis of the diaphragm. The transverse extension of a diaphragm is the extension of the diaphragm, in particular starting from a longitudinal side of the diaphragm along the transverse axis of the diaphragm. In this case, the transverse extension of the diaphragm does not necessarily extend only in the direction of the transverse axis, or may partially not extend at all in the direction of the transverse axis. If the diaphragm extends, for example, at least partially in the shape of a circular arc around the longitudinal axis of the diaphragm, then the transverse extension of the diaphragm runs partially in the direction of the transverse axis of the diaphragm and partially in the direction of the vertical axis of the diaphragm. The same applies to the longitudinal extension of the diaphragm. The vertical axis of the diaphragm is an axis perpendicular to the longitudinal axis of the diaphragm and perpendicular to the transverse axis of the diaphragm. The longitudinal axis and the transverse axis of the diaphragm are in turn perpendicular to each other.

[0052] Advantageously, the diaphragm may include at least two base sections, in particular a plurality of base sections, and / or at least two forming sections, in particular a plurality of forming sections. The base sections are elastically deformable, in particular linearly elastically, and can thus be well adapted to the shape of the workpiece or molded part to be manufactured. The forming sections are in turn plastically pre-deformed. This means that the forming sections are given a shape, in particular by plastic deformation relative to the base sections. The forming sections are additionally plastically deformed by plastic pre-deformation relative to the base sections. The plastic pre-deformation exceeds the elastic limit of the diaphragm material. The plastic pre-deformation preferably results in plastic deformation of at least the side of the forming section adjacent to the cavity and / or at least the side of the forming section adjacent to the workspace, in particular substantially across the entire thickness of the diaphragm. The shape of the forming section (in particular, imparted by the plastic pre-deformation), at least in the open position of the molding tool, in particular when the diaphragm is unloaded, advantageously differs from the basic shape of the diaphragm, in particular, the basic shape of the base section. Here, the purpose of plastic pre-deformation is to make the forming section at least partially match the shape of the workpiece or the formed part to be made from the workpiece using the equipment. Through plastic pre-deformation, the forming section can have a shape that cannot be achieved by elastic, especially linear elastic deformation of the diaphragm when manufacturing the formed part. Therefore, the shape of the forming section is matched in a controlled manner by plastic pre-deformation of the forming section, and thus the shape of the diaphragm is matched in a controlled manner, rather than the diaphragm undergoing uncontrolled plastic deformation when pressurized and / or heated. Uncontrolled plastic deformation of the diaphragm may lead to damage to the diaphragm. The forming section does not have to be completely plastic pre-deformed. It is preferably sufficient that the forming section is at least partially plastic pre-deformed, preferably mostly plastic pre-deformed. However, it can also be advantageous if the forming section is basically completely plastic pre-deformed.

[0053] In this context, the plastic pre-deformation of the forming section should not be considered to be a general plastic deformation of the entire starting material for the membrane (e.g., in a rolling mill) or any plastic deformation that the membrane may undergo during the production of the formed part when pressurized and / or heated. Preferably, the forming section is plastically pre-deformed at least on the side of the forming section adjacent to the chamber and / or at least on the side of the forming section adjacent to the working space, in particular relative to the base section.

[0054] The use of a metal diaphragm with a plastically pre-deformed section makes it possible to produce molded parts with complex geometries at high pressures and / or temperatures, something that is not possible with non-metallic diaphragms, such as silicone diaphragms. While silicone diaphragms, for example, can be well adapted to the complex geometries of a workpiece or molded part to be manufactured, they can only withstand lower pressures and / or temperatures than metal diaphragms. The lower flexibility of metal diaphragms compared to, for example, silicone diaphragms is currently compensated for by a plastically pre-deformed molded section that is adapted to the workpiece or section of the molded part to be manufactured with complex geometries. It is also advantageous if the molded section and the base section are made of the same metal. Furthermore, it can be provided that the base section and the molded section are constructed together as a single piece, in particular from sheet metal.

[0055] Furthermore, it can be provided that the shape of the second molded section corresponds to the shape of the forming section, in particular to the shape of the surface of the side of the forming section adjacent to the cavity, and / or to the shape of the surface of the side of the forming section adjacent to the working space, and / or the shape of the first molded section and / or the shape of the third molded section at least partially corresponds to the shape of the base section, in particular to the shape of the surface of the side of the base section adjacent to the cavity, and / or to the shape of the surface of the side of the base section adjacent to the working space.

[0056] The base section and the shaped section of the diaphragm are arranged in particular along the longitudinal extension and / or transverse extension of the diaphragm. The base section and the shaped section advantageously extend along the longitudinal extension and / or transverse extension of the diaphragm. Preferably, the base section and the shaped section adjoin one another, in particular along the longitudinal extension and / or transverse extension of the diaphragm.

[0057] Furthermore, it can be provided that, at least in the open position, the shaped section and / or the base section, in particular the shape of the shaped section and / or the shape of the base section, is curved at least partially about the longitudinal axis of the diaphragm or about an axis parallel to the longitudinal axis of the diaphragm, about the transverse axis of the diaphragm or about an axis parallel to the transverse axis of the diaphragm, and / or about the vertical axis of the diaphragm or about an axis parallel to the vertical axis of the diaphragm. This makes it possible to produce shaped parts with complex geometries in a simple manner. In the case of the shaped section, the curvature is imparted to the shaped section by plastic pre-deformation. It is preferably provided that, at least in the open position, the shaped section and / or the base section, in particular the shape of the shaped section and / or the shape of the base section, is curved at least partially about an axis from at least two groups of the longitudinal axes of the diaphragm, or about an axis parallel to the longitudinal axis of the diaphragm, about the transverse axis of the diaphragm or about an axis parallel to the transverse axis of the diaphragm, and about the vertical axis of the diaphragm or about an axis parallel to the vertical axis of the diaphragm. In other words, it is advantageous if, at least in the open position, the shaped section and / or the base section, in particular the shape of the shaped section and / or the shape of the base section, is at least partially curved about at least two axes running perpendicular to one another. This provides an at least partially doubly curved diaphragm. This allows for the simple production of shaped parts with complex geometries, in particular doubly curved parts. Advantageously, the shaped section, preferably the shape of the shaped section, is curved at least partially about at least two axes running perpendicular to one another by plastic pre-deformation of the shaped section, preferably relative to the base section.

[0058] Furthermore, it can be provided that, at least in the open position, the forming section (particularly the side of the forming section adjacent to the chamber and / or the side of the forming section adjacent to the working space) is at least partially spaced apart from the base section (particularly the edge region of the base section adjacent to the forming section) in the direction of the chamber and / or the working space (particularly substantially perpendicular to the surface of the edge region of the base section adjacent to the forming section), and that this spacing corresponds at least to the thickness of the membrane. This provides a forming section that is adapted to the complex geometry of the workpiece or molded part to be produced. In particular, the forming section provides sufficient space for protrusions of the workpiece or molded part to be produced, both already in the open position and during pressurization and / or application of temperature to the workpiece. Furthermore, a forming section designed in this manner can be arranged sufficiently close to recesses in the workpiece or molded part to be produced, thereby achieving uniform contact of the forming section. For example, a corresponding spacing in the direction of the chamber can indeed result in a larger chamber volume, since the distance between the membrane and the molding tool is generally increased to ensure sufficient spacing between the forming section and the molding tool. This may result in higher acquisition costs, higher operating costs, a higher risk of leakage, and higher inertia during temperature control. However, it achieves the advantage that the pressure distribution acting during the molding process is at least as uniform in the molding section as it would be if the overall process were the same. Advantageously, at least in the open position, there is a distance between the sides of the molding section adjacent to the chamber and the sides of the base section adjacent to the chamber, and / or between the sides of the molding section adjacent to the working space and the sides of the base section adjacent to the working space. Furthermore, this distance can advantageously be at least 6 mm, preferably at least 15 mm, more preferably at least 50 mm, in particular at least 72 mm, and even more preferably at least 1000 mm. Alternatively or additionally, this distance can correspond to at least 1.25 times, preferably at least 1.41 times, more preferably at least 7 times, more preferably at least 25 times, more preferably at least 50 times, and in particular at least 100 times the thickness of the diaphragm. Furthermore, the molding section can advantageously be spaced apart from the base section along the vertical axis by the aforementioned distance.

[0059] Furthermore, it can be provided that the membrane thickness of the profiled section differs from the membrane thickness of the base section, in particular from the membrane thickness of the edge region of the base section adjacent to the profiled section, by no more than 40%, preferably no more than 25%, more preferably no more than 15%, in particular no more than 10%, and even more particularly no more than 5%. This provides a membrane with a particularly uniform membrane thickness. In this case, the plastic pre-deformation of the profiled section has only a slight effect on the membrane thickness of the profiled section. Advantageously, the membrane thickness varies along substantially the entire profiled section. Furthermore, the profiled section and the base section, in particular the edge region of the base section adjacent to the profiled section, advantageously have substantially the same membrane thickness.

[0060] Furthermore, it can be provided that the forming section extends, in particular along the longitudinal extension and / or transverse extension of the membrane, for at least 6 mm, preferably at least 50 mm, further preferably at least 70 mm, further preferably at least 100 mm, further preferably at least 150 mm, further preferably at least 500 mm, and in particular at least 1000 mm. This provides a sufficiently large forming section that is also suitable for workpieces or molded parts to be produced that have larger dimensions and complex geometries.

[0061] Another design of the device is characterized in that, at least in the open position, the shape curvature of the molded section is designed to be at least partially different from at least one shape curvature of the base section, in particular along the longitudinal extension and / or transverse extension of the diaphragm, and preferably different from the shape curvature of the edge area of the base section adjacent to the molded section.

[0062] This provides the shaped segment with a pre-deformation that matches the geometry of the workpiece or shaped part to be produced. In particular, the shape curvature of the shaped segment can differ in value and / or sign from at least one shape curvature of the base segment. Thus, the shaped segment exhibits a curvature variation relative to the base segment, so that the shaped segment and the base segment extend at least partially in different directions. The shape of the shaped segment or the shape of the base segment describes the general shape of the respective segment.

[0063] Structural deviations, preferably of at least the second and / or at least the third and higher order, as described in DIN 4760:1982-06, are not considered part of the shape or the shape curvature. Second-order structural deviations are waviness, and third- to fifth-order structural deviations are roughness. Therefore, shape curvature is not a defect, in particular a surface defect, of the diaphragm. In particular, the shape curvature of the profiled segment is at least partially smaller or larger by a factor of at least 1.05, preferably at least 1.25, more preferably at least 2, more preferably at least 4, more preferably at least 10, more preferably at least 25, more preferably at least 50, more preferably at least 100, more preferably at least 250, more preferably at least 500, more preferably at least 1000, more preferably at least 250, more preferably at least 500, more preferably at least 1000, more preferably at least 2500, more preferably at least 5000, and in particular at least 10,000, than at least one shape curvature of the base segment, preferably at least 5000, more preferably at least 10, ...

[0064] Advantageously, the difference in curvature between the shape of the shaped section and at least one curvature of the shape of the base section is at least partially generated by plastic pre-deformation of the shaped section, in particular relative to the base section. Thus, the difference in curvature should not, or at least should not be substantially due to a difference in curvature caused by elastic deformation of the diaphragm, in particular due to gravity.

[0065] Furthermore, it can be provided that, at least in the open position, the shape curvature of the side of the forming segment of the forming segment adjoining the cavity differs at least partially from at least one shape curvature of the side of the base segment of the base segment adjoining the cavity (preferably the shape curvature of an edge region of the base segment adjoining the forming segment), and / or the shape curvature of the side of the forming segment of the forming segment adjoining the working space differs at least partially from at least one shape curvature of the side of the base segment of the base segment adjoining the working space (preferably the shape curvature of an edge region of the base segment adjoining the forming segment). This provides the forming segment with a pre-deformation adapted to the geometry of the workpiece or molded part to be produced. It is particularly advantageous if not only the curvature of the side adjoining the working space but also the curvature of the side adjoining the cavity differ from each other, since this allows for a particularly wide range of adaptation of the forming segment to the geometry of the workpiece or molded part to be produced.

[0066] Another embodiment of the device provides that, at least in the open position, the curvature of the shaped section is designed to be at least partially opposite to at least one curvature of the base section, preferably opposite to the curvature of the edge region of the base section adjacent to the shaped section, particularly along the longitudinal and / or transverse extension of the diaphragm. This provides the shaped section with a pre-deformation adapted to the geometry of the workpiece or molded part to be produced. In particular, this provides a shaped section that is pre-formed to more complex geometries of the workpiece or molded part to be produced. In this context, the term "opposite curvature" is to be understood as meaning the definition already explained in connection with the embossing section.

[0067] Advantageously, plastic pre-deformation of the profiled section, in particular relative to the base section, at least partially generates an opposite curvature between the shape of the profiled section and at least one curvature of the shape of the base section. Thus, the opposite curvature should not, for example, be caused, or at least not substantially caused, by elastic deformation of the membrane (in particular due to gravity).

[0068] Furthermore, it can be provided that, at least in the open position, the shape curvature of the side of the forming section adjoining the cavity is designed to be at least partially opposite to at least one shape curvature of the side of the base section adjoining the cavity (preferably the shape curvature of the edge region of the base section adjoining the forming section), and / or the shape curvature of the side of the forming section adjoining the working space is designed to be at least partially opposite to at least one shape curvature of the side of the base section adjoining the working space (preferably the shape curvature of the edge region of the base section adjoining the forming section). This provides the forming section with a pre-deformation adapted to the geometry of the workpiece or molded part to be produced. It is particularly advantageous if both the curvature of the side adjoining the working space and the curvature of the side adjoining the cavity are designed to be opposite, since this allows for a particularly wide range of adaptation of the forming section to the geometry of the workpiece or molded part to be produced.

[0069] According to another embodiment of the device, a deviation of the shape curvature of the shaped segment from at least one shape curvature of the base segment (preferably from the shape curvature of an edge region of the base segment adjacent to the shaped segment) is generated by plastic deformation, in particular of the shape of the shaped segment. Thus, the difference in curvature, i.e., the difference in curvature value and / or sign, is to be generated by plastic pre-deforming the shaped segment. This allows the shaped segment to be continuously adapted to the geometry of the workpiece or shaped part to be produced.

[0070] Another design of the device provides that the chamber is sealed by at least one seal, at least in the closed position, and / or the device includes at least one device for varying the diaphragm preload. The corresponding seals prevent the working medium from escaping the chamber in a structurally simple manner. The device for varying the diaphragm preload has the advantage that, in particular, the diaphragm is already evenly positioned against the workpiece before or at the start of applying temperature and pressure to the workpiece. The device for varying the diaphragm preload can, for example, be implemented using a spring with an adjustable spring travel or preload. Regarding the seal, it can also be provided that a sealing force can be applied to the diaphragm by means of the seal, and preferably the diaphragm is movable relative to the seal. By enabling the diaphragm to move relative to the seal, changes in the diaphragm's length, particularly due to thermal expansion or contraction, do not result in the diaphragm being overstressed or unevenly positioned against the workpiece or molded part to be manufactured. Furthermore, the ability of the diaphragm to move relative to the seal simplifies diaphragm preload, as the preload can then be applied to the diaphragm outside the area sealed by the seal. Advantageously, it is provided that the device comprises at least one device for varying the sealing force of the seal, thereby making it possible to seal the chamber particularly tightly.

[0071] Furthermore, the object stated at the outset is achieved by a method for producing a molded part, in particular one made of a fiber composite material, comprising the following steps: a) providing a workpiece, b) providing an apparatus for producing a molded part according to any one of claims 1 to 14, and c) applying pressure and / or temperature to the workpiece using the apparatus for producing the molded part. Furthermore, the method advantageously includes the step b1) of inserting the workpiece into the apparatus for producing the molded part. Preferably, the workpiece is inserted into a workspace in step b1). Furthermore, the molding tool is advantageously in an open position in step b1). Preferably, the method further includes the step b2) of moving the first molding tool and the second molding tool from the open position into a closed position. Preferably, steps b1) and / or b2) are performed after steps a) and / or b). Alternatively or additionally, it is also preferred that steps b1) and / or b2) are performed before step c). It is also preferred that step b1) be performed before step b2). BRIEF DESCRIPTION OF THE DRAWINGS

[0072] The invention is explained in more detail below with the aid of the accompanying drawings which show only preferred exemplary embodiments.

[0073] It shows:

[0074] Figure 1 A first embodiment of a device for producing molded parts is shown in section, wherein the molding tool of the device is in an open position.

[0075] Figure 2 Show the basis Figure 1 a device wherein the workpiece is placed in a working space of the device and the molding tool of the device is in an open position,

[0076] Figure 3 Show the basis Figure 1 a device wherein the workpiece is placed in a working space of the device and the molding tool of the device is in a closed position,

[0077] Figure 4 A second embodiment of a device for producing molded parts is shown in section, wherein the molding tool of the device is in an open position.

[0078] Figure 5 Show the basis Figure 4 a device wherein the workpiece is placed in a working space of the device and the molding tool of the device is in an open position,

[0079] Figure 6 Show the basis Figure 4 an apparatus wherein the workpiece is placed in a working space of the apparatus and the molding tool of the apparatus is in a closed position, and

[0080] Figure 7 A detail of a third embodiment of a device for producing molded parts is shown in section, wherein the molding tool of the device is in a closed position. DETAILED DESCRIPTION

[0081] Figure 1 A first embodiment of a device 1 for producing molded parts is shown in section, wherein the molding tools 2, 3 of the device are in an open position. At this time, no workpiece has yet been placed in the device.

[0082] The apparatus 1 comprises a first upper moulding tool 2 and a second lower moulding tool 3. The two moulding tools 2, 3 can be moved relative to each other along a movement axis B between an open position and a closed position, for example in a vertical direction (in Figure 1 Here, it is sufficient that only one of the two embossing tools 2, 3, in particular the first embossing tool 2, is movably supported. The axis of motion B can be, for example, Figure 1 Extends vertically as shown.

[0083] Furthermore, the device 1 comprises a membrane 4 which, in the present embodiment, is connected to the first embossing tool 2. Figure 1 In the design shown in FIG, the diaphragm 4 can also be connected to the second molding tool 3, for example. A chamber 5 for a working medium, such as oil, is formed between the diaphragm 4 and the first molding tool 2. The diaphragm 4 is made of metal and preferably has a thickness ranging from 0.05 mm to 4 mm. The chamber 5 can be filled with the working medium via a channel 6. Holes 7 are provided in both the first molding tool 2 and the second molding tool 3, through which a heating medium and / or a cooling medium can be guided. Alternatively or additionally, the first molding tool 2 and / or the second molding tool 3 can also include a heating element, in particular an insertable heating plate, that can be inserted into the respective molding tool 2, 3.

[0084] exist Figure 1 In the embodiment of the device 1 shown in FIG, a working space 8 is formed between the two molding tools 2, 3, wherein the working space 8 is currently formed in particular between the membrane 4 and the second molding tool 3. Figure 1 The two embossing tools 2 , 3 preferably have a guide 9 which can be formed, for example, by a projection 9A and a recess 9B, wherein the projection 9A can be provided on the second embossing tool 3 and the recess 9B can be provided on the first embossing tool 2 .

[0085] In the present embodiment, the surface of the first molding tool 2 and the surface of the second molding tool 3 each have a first molding section P1, P1', a second molding section P2, P2', and a third molding section P3, P3'. Here, the molding sections P1, P2, P3 of the first molding tool 2 adjoin the cavity 5, and the molding sections P1', P2', P3' of the second molding tool 3 adjoin the workspace 8. However, it may also be sufficient for only one of the molding tools 2, 3 to have a correspondingly designed surface with the corresponding molding sections P1, P1', P2, P2', P3, P3'.

[0086] The second molding sections P2, P2' and the third molding sections P3, P3' of the two molding tools 2, 3 are respectively at least partially spaced apart from the first molding sections P1, P1' of the corresponding molding tools 2, 3. In addition, the shape curvature of the second molding sections P2, P2' of the two molding tools 2, 3 is designed to be at least partially different from, and at least partially opposite to, the shape curvature of the corresponding first molding sections P1, P1' and the shape curvature of the corresponding third molding sections P3, P3'.

[0087] In this case, the respective second stamping sections P2, P2' of the two stamping tools 2, 3 each comprise a first bend KP1, KP1' and a second bend KP2, KP2'. In the region of the bends KP1, KP1', KP2, KP2', the shape of the second stamping sections P2, P2' has a different curvature than the shape of the first stamping sections P1, P1' and the shape of the third stamping sections P3, P3'. This curvature differs not only in value but also in sign. Consequently, the first stamping sections P1, P1' and the third stamping sections P3, P3' each have a zero curvature, particularly in the edge regions adjacent to the respective second stamping sections P2, P2', because the first stamping sections P1, P1' and the third stamping sections P3, P3' each extend straight. In contrast, the second stamping sections P2, P2' have a non-zero curvature in the region of the bends KP1, KP1', KP2, KP2' and therefore have a curvature that differs from the curvature of the respective first stamping sections P1, P1' and third stamping sections P3, P3'. However, the respective bends can also be provided in the respective first stamping sections P1, P1' and / or third stamping sections P3, P3'.

[0088] In the present embodiment, the second die sections P2, P2' do not extend parallel to the respective first die sections P1, P1' and the respective third die sections P3, P3', but rather extend partially obliquely. In the illustrated embodiment, a 45° angle exists between the respective second die sections P2, P2' and the respective first die sections P1, P1' and the respective third die sections P3, P3'.

[0089] In the embodiment shown, the membrane 4 is connected to the first embossing tool 2 in the following manner: the first embossing tool 2 has a circumferential edge element 10, which is connected to the first embossing tool 2, in particular screwed (at Figure 1 (This tightening is not shown in the figure). A gap 11 is formed between the first embossing tool 2 and its edge element 10, through which the diaphragm 4 is guided. This gap 11 opens into a cavity 12, in which a clamping device 13 is located, into which the diaphragm 4 is clamped. The clamping device 13 is connected to a tie rod 14, which is guided through an opening from the first embossing tool 2 and the edge element 10 and is there urged outward by a spring 15 supported on the outer surface, thereby providing a preload on the diaphragm 4. The spring 15 is an integral part of the device for varying the preload on the diaphragm 4.

[0090] To seal the chamber 5, a seal 16 is provided in the gap 11, which seal allows the movement of the membrane 4. The seal 16 presses with a sealing force onto the membrane 4. In order to change the sealing force, a device 17 for changing the sealing force of the seal 16 is provided.

[0091] In the current Figure 1 In the view shown, the transverse axis Q of the diaphragm 4 extends from left to right, and the longitudinal axis L of the diaphragm 4 enters Figure 1 The vertical axis H of the diaphragm 4 extends from bottom to top. Figure 1 and subsequent figures are drawn accordingly. Figure 1 In the embodiment, the transverse extension of the diaphragm 4 is substantially from left to right or from right to left, and the longitudinal extension of the diaphragm 4 is substantially into Figure 1 In the plane of the figure or from Figure 1 The plane of the drawing runs outward. In this embodiment (and other embodiments), the transverse axis Q of the diaphragm 4, the transverse axis of the device 1, the transverse axis of the first molding tool 2, and the transverse axis of the second molding tool 3 respectively run in the same direction, the longitudinal axis L of the diaphragm 4, the longitudinal axis L of the device 1, the longitudinal axis of the first molding tool 2, and the longitudinal axis of the second molding tool 3 respectively run in the same direction, and the vertical axis H of the diaphragm 4, the vertical axis H of the device 1, the vertical axis of the first molding tool 2, and the vertical axis of the second molding tool 3 respectively run in the same direction, so the same figure mark is currently used for each corresponding axis. Therefore, the lateral extension of the molding tools 2 and 3 also basically runs from left to right or from right to left, and the longitudinal extension of the molding tools 2 and 3 also basically enters Figure 1 The plane of the graph or from Figure 1 The plane of the drawing extends outward.

[0092] The diaphragm 4 has at least one elastically deformable base section G, G', which is used to contact a workpiece, particularly also for contacting a molded part to be produced, and at least one plastically pre-deformed molded section F, which is used to contact a workpiece, particularly also for contacting a molded part to be produced. In the presently illustrated embodiment of the apparatus 1, a first base section G is provided along the lateral extent of the diaphragm 4, a molded section F is provided adjacent to the first base section G, and a second base section G' is provided adjacent to the molded section F. The molded section F is plastically pre-deformed relative to the base sections G, G'. This plastic pre-deformation imparts a shape to the molded section F that differs from at least one base section G, G', and preferably from both base sections G, G'. In the present embodiment, the molded section F does not extend parallel to the base sections G, G', but rather partially extends at an angle relative to the base sections G, G'. The plastic pre-deformation of the molded section F enables the apparatus 1 to process workpieces with complex geometries and produce molded parts having complex geometries. In particular, in the case of an apparatus 1 having a diaphragm 4 made of metal, elastic deformation of the diaphragm 4 is only possible to a certain extent in order to use the diaphragm 4 to follow the shape of a workpiece or a molded part to be produced having a complex geometry.

[0093] Due to the plastic pre-deformation of the profiled section F, the base sections G, G' can be deformed more elastically than the profiled section F. Compared to the profiled section F, the base sections G, G' can be deformed more elastically, in particular linearly elastically, in the direction of the working space 8. Nevertheless, the profiled section F can still be deformed elastically at least to a certain extent.

[0094] Here, the shaped section F currently has bends K, K' on its outer region along the lateral extension of the diaphragm 4. These bends K, K' in the diaphragm 4 are generated by plastic pre-deformation of the shaped section F relative to the base sections G, G'. In the region of the bends K, K', the shape of the shaped section F has a different curvature than that of the base sections G, G', not only in terms of the value of the curvature but also in terms of the sign of the curvature. Therefore, the base sections G, G', and in particular the edge regions of the respective base sections G, G' adjacent to the shaped section F, have a curvature of zero, since the base sections G, G' each extend straight. In contrast, the shaped section F has a non-zero curvature in the region of the bends K, K' and therefore has a different curvature than that of the base sections G, G'.

[0095] Here, the difference in curvature and the existence of opposite curvatures currently exist not only between the shape curvature of the side of the forming segment F adjacent to the cavity 5 and the shape curvature of the side of the basic segment G, G' adjacent to the cavity 5 (preferably the shape curvature of the edge area of the basic segment G, G' respectively adjacent to the forming segment F), but also between the shape curvature of the side of the forming segment F adjacent to the working space 8 and the shape curvature of the side of the basic segment G, G' adjacent to the working space 8 (preferably the shape curvature of the edge area of the basic segment G, G' respectively adjacent to the forming segment F).

[0096] In this case, the molded section F extends partially obliquely relative to the base sections G, G', in particular at an angle of 45°. In this case, the molded section F (particularly the side of the molded section F adjoining the chamber 5 and the side of the molded section F adjoining the working space 8) is at least partially spaced apart from the first base section G (particularly the edge region of the first base section G adjoining the molded section F) in the direction of the chamber 5 (particularly substantially perpendicular to the surface of the edge region of the first base section G) and partially spaced apart from the second base section G' (particularly the edge region of the second base section G' adjoining the molded section F) in the direction of the working space 8 (particularly substantially perpendicular to the surface of the edge region of the second base section G'), wherein the distance corresponds at least to the membrane thickness.

[0097] In this case, at least part of the curvature difference between the shape of the profiled section F and the shape of the base sections G, G' is generated by means of plastic deformation, in particular by means of plastic pre-deformation, of the profiled section F. Despite this plastic deformation or plastic pre-deformation, the membrane thickness of the profiled section F differs from the membrane thickness of the base sections G, G' by a maximum of 40%.

[0098] Figure 2 Show the basis Figure 1 1, wherein a workpiece 18 is placed in the working space 8 of the apparatus 1 and the embossing tools 2, 3 of the apparatus 1 are in an open position. The areas of the apparatus 1 which have already been described are Figure 2 The corresponding reference numerals are provided in FIG. Figure 1 The difference is that the workpiece 18 is already placed in the working space 8 .

[0099] Figure 3 Show the basis Figure 1 The device 1 is a device 1 in which a workpiece 18 is placed in the working space 8 of the device 1 and the molding tools 2, 3 of the device 1 are in a closed position. The areas of the device 1 which have been described above are Figure 3The device 1 is closed and the embossing tools 2, 3 are therefore in a closed position by moving the two embossing tools 2, 3 towards each other. Figure 3 In the closed position shown, the workpiece 18 is pressurized and heated. Pressurization is achieved by guiding a working medium, such as oil, through the channel 6 into the chamber 5, thereby pressing the diaphragm 4 toward the workpiece 18. The temperature can be applied in various ways: One possibility is to heat the working medium guided through the channel 6 into the chamber 5, so that heat is transferred from the working medium in the chamber 5 via the diaphragm 4 to the workpiece 18. Conversely, the working medium can be cooled to cool the workpiece 18. Alternatively or in addition, it can be provided that a heating and / or cooling medium flows through the opening 7, thereby first heating or cooling the two molding tools 2, 3 and then also the workpiece 18.

[0100] Figure 4 A second embodiment of a device for producing a molded part 1 is shown in section, wherein the molding tools 2, 3 of the device 1 are in the open position. The workpiece 18 has not yet been placed in the working space 8 of the device 1. Figure 4 The second embodiment of the device 1 shown in FIG. Figures 1 to 3 The first embodiment of the apparatus 1 shown in FIG. 1 differs substantially in the shape of the embossing tools 2 and 3, in particular the shape of the embossing sections P1, P1', P2, P2', P3, P3', and the shape of the membrane 4. Identical components of the embodiments are also given the same reference numerals. Below, only the differences in the embodiments are discussed in detail.

[0101] In a second embodiment of the device 1, the stamping sections P1, P1', P2, P2', P3, P3' initially have a shape that is composed, in particular, of a plurality of circular arcs. The two stamping tools 2, 3 themselves also have, at least in part, a shape that is composed, in particular, of a plurality of circular arcs. However, the shape of the stamping tools 2, 3 on the side facing away from the chamber 5 and / or the workspace 8 can also be designed differently. The second stamping sections P2, P2' of the stamping tools 2, 3 each have a substantially S-shaped shape. The shape of the second stamping sections P2, P2', but also the shape of the first stamping sections P1, P1' and the third stamping sections P3, P3', is adapted to the complex geometry of the workpiece 18 and the molded part to be produced therefrom, which can be placed in the workspace 8 of the device 1. Here, the shape curvature of the second stamped sections P2, P2' is designed to be partially different, in particular partially opposite, relative to the shape curvature of the corresponding first stamped sections P1, P1' and the corresponding third stamped sections P3, P3', respectively, and in particular relative to the shape curvature of the edge areas of the corresponding first stamped sections P1, P1' and the corresponding third stamped sections P3, P3', respectively, which are adjacent to the corresponding second stamped sections P2, P2'. Thus, for example, the shape curvature of the second stamped sections P2, P2' in the region of the third bend KP3, KP3' runs opposite to at least one shape curvature of the corresponding first stamped sections P1, P1' and the corresponding third stamped sections P3, P3'. Due to the shape complexity of the corresponding second stamped sections P2, P2', it can also be provided that the second stamped sections P2, P2' are each divided into further stamped sections.

[0102] Furthermore, in the present embodiment, the diaphragm 4 partially has a shape that is primarily composed of a plurality of circular arcs. The base sections G, G' have a substantially continuous curvature due to elastic deformation (in this case due to gravity). Due to the plastic pre-deformation, in particular relative to the base sections G, G', the plastically pre-deformed forming section F has a substantially S-shaped shape. The shape of the forming section F is adapted to the complex geometry of the workpiece 18 and the formed part to be manufactured therefrom. The shape curvature of the forming section F is designed to be at least partially different, in particular at least partially opposite, along the lateral extension of the diaphragm 4 relative to the curvature of the edge regions of the respective base sections G, G' that are adjacent to the forming section F. Therefore, in the region of the first bend K and the third bend K" of the diaphragm 4, the shape curvature of the forming section F runs in the opposite direction to the shape curvature of the base sections G, G'.

[0103] Figure 5 Show the basis Figure 4 The device 1 is shown in FIG. 1 , wherein a workpiece 18 is placed in the working space 8 of the device 1 and the molding tools 2 , 3 of the device 1 are in the open position. The areas of the device 1 already described are shown in FIG. Figure 4 The corresponding reference numerals are provided in FIG. Figure 4 The difference is that the workpiece 18 is already placed in the working space 8 .

[0104] Figure 6 Show the basis Figure 4 The device 1 is a device 1 in which a workpiece 18 is placed in the working space 8 of the device 1 and the molding tools 2, 3 of the device 1 are in a closed position. The areas of the device 1 which have been described above are Figure 6 Corresponding reference numerals are also provided in FIG. Figure 3 , device 1 is closed. Figure 3 The description can be transferred accordingly to Figure 6 superior.

[0105] Figure 7 A detail of a third embodiment of a device for producing a molded part 1 is shown in section, wherein the molding tools 2 , 3 of the device 1 are in a closed position, wherein a workpiece 18 is placed in the working space 8 . Figure 7 The third embodiment of the device 1 shown in FIG. Figures 1 to 3 The first embodiment of the device 1 shown in Figures 4 to 6 The second embodiment of the device 1 shown in FIG. 1 differs substantially in the shape of the embossing tools 2, 3, in particular in the shape of the embossing sections P1, P1', P2, P2', P3, P3' and in the shape of the membrane 4. Identical components of the embodiments also have the same reference numerals. In particular, the unillustrated areas of the device 1 of this third embodiment may correspond to Figures 1 to 6 Basically, only the differences of this embodiment with respect to the previous embodiment will be discussed in detail below.

[0106] In the present third embodiment, both the first embossing sections P1, P1' and the third embossing sections P3, P3' are designed as circular arcs. The second embossing sections P2, P2' are designed differently, that is, the respective second embossing sections P2, P2' are designed as circular arcs.

[0107] The shape curvature of the ' is designed to be at least partially different and opposite to the shape curvature of the first and third molded sections P1, P1' and P3, P3' respectively adjacent to each other. Thus, for example, the shape curvature of the second molded sections P2, P2' is different in the first bending portion KP1, KP1

[0108] In the region of ', the curvature runs opposite to the shape of the corresponding first molded section P1, P1' and the corresponding third molded section P3, P3'. In the embodiment shown, the second molded sections P2, P2' are each designed to be approximately S-shaped and include a straight region, but the second molded sections P2, P2' can also each have a substantially continuously curved shape.

[0109] Due to the plastic pre-deformation, particularly relative to the base sections G, G', the plastically pre-deformed forming section F accordingly has a roughly S-shaped shape. While the forming section F comprises straight regions, it can also have a substantially continuously curved shape. The shape of the forming section F is adapted to the complex geometry of the workpiece 18 and the molded part to be manufactured therefrom. Furthermore, the curvature of the shape of the forming section F is designed to be at least partially opposite to the curvature of the edge regions of the respective base sections G, G' that are adjacent to the forming section F, along the lateral extension of the diaphragm 4. Thus, for example, in the region of the first bend K of the diaphragm 4, the curvature of the shape of the forming section F runs opposite to the curvature of the shape of the base sections G, G'.

[0110] Description of Reference Numerals

[0111] 1Equipment for manufacturing molded parts

[0112] 2First molding tool

[0113] 3 Second molding tool

[0114] 4 diaphragms

[0115] 5 chambers

[0116] 6 channels

[0117] 7 holes

[0118] 8 Workspace

[0119] 9. Guidance Department

[0120] 9A convex part

[0121] 9B concave part

[0122] 10 edge components

[0123] 11 gap

[0124] 12 cavities

[0125] 13 Clamping device

[0126] 14 tie rod

[0127] 15 spring

[0128] 16 seals

[0129] 17. Device for changing sealing force

[0130] 18 workpieces

[0131] B motion axis F forming section G, G' base section H vertical axis

[0132] K, K', K" Bends of the membrane KP1, KP1', KP2, KP2', KP3, KP3' Bends of the molding tool L Longitudinal axis

[0133] P1, P1' first molding section P2, P2' second molding section P3, P3' third molding section

[0134] Q horizontal axis

Claims

1. A device for producing a molded part (1), in particular made of a fiber composite material, comprising: - a first moulding tool (2), - a second moulding tool (3), and at least one at least partially elastically deformable membrane (4) for contacting a workpiece (18), - wherein the first moulding tool (2) and the second moulding tool (3) are movable relative to each other along a movement axis (B) between an open position and a closed position, wherein a chamber (5) for the working medium is formed between the diaphragm (4) and the first embossing tool (2) and / or the second embossing tool (3), at least in the closed position, wherein a working space (8) for accommodating a workpiece (18) is formed between the first embossing tool (2) and the second embossing tool (3), wherein the surface of the first embossing tool (2) and / or the surface of the second embossing tool (3) comprises a first embossing section (P1, P1') and a second embossing section (P2, P2'), - wherein the first molding section (P1, P1') and the second molding section (P2, P2') are adjacent to the working space (8) and / or the chamber (5), and - wherein the diaphragm (4) is made of metal, It is characterized by: The second stamping section (P2, P2') is at least partially separated from the first stamping section (P1, P1') in the direction of the movement axis (B), and at least one shape curvature of the second stamping section (P2, P2') is designed to be different from at least one shape curvature of the first stamping section (P1, P1'), in particular along the longitudinal extension and / or transverse extension of the corresponding stamping tool (2, 3), preferably different from the shape curvature of the edge area of the second stamping section (P2, P2') adjacent to the first stamping section (P1, P1').

2. The device (1) according to claim 1, characterized in that The second molding section (P2, P2') is at least partially separated from the first molding section (P1, P1') along the direction of the movement axis (B) by a spacing of at least 5 mm, preferably at least 50 mm, further preferably at least 150 mm, further preferably at least 200 mm, further preferably at least 300 mm, further preferably at least 500 mm, and in particular at least 1000 mm.

3. The device (1) according to claim 1 or 2, characterized in that At least one shape curvature of the second molding section (P2, P2') is designed to be at least partially opposite to at least one shape curvature of the first molding section (P1, P1'), preferably opposite to the shape curvature of the edge area of the first molding section (P1, P1') adjacent to the second molding section (P2, P2'), in particular along the longitudinal extension and / or transverse extension of the corresponding molding tool (2, 3).

4. The device (1) according to any one of claims 1 to 3, characterized in that The second embossing section (P2, P2') extends, in particular, along the longitudinal extension and / or transverse extension of the respective embossing tool (2, 3), at least partially obliquely to the first embossing section (P1, P1'), and preferably, there is at least partially an angle between the first embossing section (P1, P1') and the second embossing section (P2, P2'), which angle is at least 90°, preferably at least 100°, in particular at least 120°, and / or at most 180°, preferably at most 160°, in particular at most 145°.

5. The device (1) according to any one of claims 1 to 4, characterized in that The surface of the first molding tool (2) and / or the surface of the second molding tool (3) has a third molding section (P3, P3'), preferably, the third molding section (P3, P3') is at least partially spaced apart from the first molding section (P1, P1') and / or the second molding section (P2, P2') along the direction of the movement axis (B), and preferably, the third molding section (P3, P3') is at least partially spaced apart from the first molding section (P1, P1') and / or the second molding section (P2, P2') along the direction of the movement axis (B) at a distance of at least 5 mm, preferably at least 50 mm, further preferably at least 150 mm, further preferably at least 200 mm, further preferably at least 300 mm, further preferably at least 500 mm, and in particular at least 1000 mm.

6. The device (1) according to claim 5, characterized in that At least one shape curvature of the third molding segment (P3, P3') is designed to be at least partially different from at least one shape curvature of the first molding segment (P1, P1'), in particular along the longitudinal extension and / or transverse extension of the corresponding molding tool (2, 3), and / or at least one shape curvature of the third molding segment (P3, P3') is designed to be at least partially different from at least one shape curvature of the second molding segment (P2, P2'), preferably different from the shape curvature of the edge area of the third molding segment (P3, P3') adjacent to the second molding segment (P2, P2').

7. The device (1) according to claim 5 or 6, characterized in that At least one shape curvature of the third molding section (P3, P3') is designed to be at least partially opposite to at least one shape curvature of the first molding section (P1, P1'), in particular along the longitudinal extension and / or lateral extension of the corresponding molding tool (2, 3), and / or at least one shape curvature of the third molding section (P3, P3') is designed to be at least partially opposite to at least one shape curvature of the second molding section (P2, P2'), in particular along the longitudinal extension and / or lateral extension of the corresponding molding tool (2, 3), preferably opposite to the shape curvature of the edge area of the second molding section (P2, P2') adjacent to the third molding section (P3, P3').

8. The device (1) according to any one of claims 5 to 7, characterized in that The third embossing section (P3, P3') extends, in particular, along the longitudinal extension and / or transverse extension of the respective embossing tool (2, 3), at least partially obliquely relative to the first embossing section (P1, P1') and / or the second embossing section (P2, P2'), and preferably, there is at least partially an angle between the third embossing section (P3, P3') and the first embossing section (P1, P1') and / or the second embossing section (P2, P2'), which angle is at least 90°, preferably at least 100°, in particular at least 120°, and / or the angle is a maximum of 180°, preferably a maximum of 160°, in particular a maximum of 145°.

9. The device (1) according to any one of claims 1 to 8, characterized in that The first molded section (P1, P1'), the second molded section (P2, P2') and / or the third molded section (P3, P3'), in particular the shape of the first molded section (P1, P1'), the shape of the second molded section (P2, P2') and / or the shape of the third molded section (P3, P3'), are at least partially bent around the longitudinal axis (L) of the device (1) or around an axis parallel to the longitudinal axis (L) of the device (1), around the transverse axis (Q) of the device (1) or around an axis parallel to the transverse axis (Q) of the device (1), and / or around the vertical axis (H) of the device (1) or around an axis parallel to the vertical axis (H) of the device (1).

10. The device (1) according to any one of claims 1 to 9, characterized in that The diaphragm (4) has, in particular, along the longitudinal extension and / or transverse extension of the diaphragm (4), at least one elastically deformable base section (G, G') for contacting a workpiece (18), and at least one plastically pre-deformed forming section (F) for contacting the workpiece (18), and preferably, at least in the open position, the forming section (F) is plastically pre-deformed relative to the base section (G, G'), in particular along the longitudinal extension and / or transverse extension of the diaphragm (4).

11. The device (1) according to claim 10, characterized in that At least in the open position, the shape curvature of the formed segment (F) is designed to be at least partially different from at least one shape curvature of the base segment (G, G'), preferably different from the shape curvature of the edge area of the adjacent formed segment (F) of the base segment (G, G'), in particular along the longitudinal extension and / or transverse extension of the diaphragm (4).

12. The device (1) according to claim 10 or 11, characterized in that At least in the open position, the shape curvature of the molded section (F) is designed to be at least partially opposite to at least one shape curvature of the base section (G, G'), preferably opposite to the shape curvature of the edge area of the adjacent molded section (F) of the base section (G, G'), in particular along the longitudinal extension and / or transverse extension of the diaphragm (4).

13. The device (1) according to claim 11 or 12, characterized in that The difference in shape curvature of the shaped segment (F) relative to at least one shape curvature of the base segment (G, G'), preferably the difference in shape curvature of the edge area of the adjacent shaped segment (F) relative to the base segment (G, G'), is generated by means of plastic deformation, in particular of the shape, of the shaped segment (F).

14. The device (1) according to any one of claims 1 to 13, characterized in that The chamber (5) is sealed at least in the closed position by at least one seal (16), and / or the device (1) comprises at least one device for varying the preload of the membrane (4).

15. A method for producing a molded part, in particular made of a fiber composite material, comprising the following steps: a) providing a workpiece (18), b) providing an apparatus for producing a molded part (1) according to any one of claims 1 to 14, and c) applying pressure and / or temperature to the workpiece (18) by means of a device for producing a molded part (1).

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