Shaping and expanding tool

Abstract

The invention relates to a forming and expanding tool having a first mold and a second mold and a space between the first mold and the second mold accommodating a sheet to be formed and expanded. The invention also relates to a method of forming and expanding a sheet.

Description

Technical Field

[0001] This invention relates to a forming and expanding tool having a first mold and a second mold, and a space located between the first mold and the second mold for receiving a sheet to be formed and expanded. The invention also relates to a method for forming and expanding a sheet. Background Technology

[0002] In automotive applications, large components are needed for sound insulation, such as between the engine and the passenger compartment or as the passenger compartment floor. These components are three-dimensionally shaped and include expandable layers that are expanded in forming and expanding tools. These tools are large and therefore difficult to operate and / or manufacture, and the process of forming and expanding the sheets is difficult to control.

[0003] Therefore, there is always a need to improve such tools and / or methods for forming and expanding sheets. Summary of the Invention

[0004] The problem is solved by forming and expanding tools having a first mold and a second mold and a space between the first mold and the second mold for receiving the sheet to be formed and expanded, wherein the first mold and / or the second mold is provided by multiple segments.

[0005] The disclosures made regarding this topic also apply to other topics, and vice versa. Topics disclosed in the context of one topic can be incorporated into other topics.

[0006] The subject of this invention relates to tools for forming and expanding sheets.

[0007] The sheet is preferably used in automotive applications, particularly truck applications. For example, the sheet can be used as a passenger cabin floor. The sheet preferably has a large extension, for example, greater than half a square meter, more preferably >0.7 square meters. The sheet is conventionally three-dimensionally shaped. Preferably, the sheet is a sandwich of two metal layers (preferably at least one aluminum layer) and an intermediate expandable polymeric material, with the two metal layers serving as two opposite surface layers of the sheet. At least one surface layer is preferably embossed, for example, having an anti-slip structure. The pressure generated by the expansion of the polymeric material at least helps to shape the sheet into its final form. Preferably, this embossing is maintained during the shaping and expansion of the sheet.

[0008] The expansion of the expandable polymeric material is preferably carried out under the influence of heat, for example, by activating a foaming agent. The expansion of the sheet increases the distance between two opposing surface layers. After expansion, the polymeric material is preferably cured to maintain the sheet in its final expanded form and provide rigidity. This sheet is preferably used for noise reduction and as thermal insulation.

[0009] According to the invention, the forming and expanding tool includes a first mold and a second mold (preferably two opposing molds), such as an upper mold and a lower mold, which cooperate to provide a desired shape for the sheet. Preferably, the two molds can be moved relative to each other from a remote position to a forming position. The molds are preferably made of metal, more preferably aluminum. Preferably, at least one mold can be heated, more preferably both molds can be heated.

[0010] Creatively, the first mold and / or the second mold are provided by multiple segments. Each segment preferably extends along one or two entire dimensions (e.g., the height and width of the mold). A third dimension, such as length, is divided into multiple segments. The thickness of the segments can be selected independently. Potential selection criteria are the accuracy of temperature control of the forming surface and / or the weight and / or wear of the segments. The segments are preferably placed side by side along a third direction. Each segment preferably provides a portion of the forming surface that contacts the sheet to be formed and expanded. The segment is preferably hollowed out in an area on the opposite side of the forming surface where mechanical rigidity is not required. This reduces the thermal inertia of the segment.

[0011] Preferably, the segments are connected to a frame. The frame is preferably positioned on opposite sides of the shaped surfaces of the segments. The frame is preferably rectangular or square. The frame may include crossbeams, which preferably extend from one side of the frame to the opposite side. Preferably, each segment is individually supported at the frame. At its central portion, the segment may be supported at the frame, for example by one or more punches and / or one or more pillars.

[0012] According to a preferred embodiment of the invention, thermal insulation is provided between the segment and the frame and / or between the support element and the segment, for example to avoid heat loss and / or deformation / thermal expansion of the frame and / or the support element.

[0013] Preferably, the segments are connected to each other by connecting elements, such as screws. Preferably, two adjacent segments are connected to each other. The connecting elements are preferably located near the periphery of the segments.

[0014] Preferably, one or two molds are heated to support the forming of the sheet and / or to induce the expansion of the polymeric material. According to a preferred embodiment of the invention, a heating element, preferably an electric heating element, is disposed adjacent to the forming surface of the mold, and more preferably between two adjacent segments. Preferably, the heating element is disposed in a groove, which more preferably extends parallel to and adjacent to the forming surface and / or segments of the mold. Preferably, the heating element is disposed parallel to the forming surface of the mold. Preferably, the shape of the heating element conforms to the shape of the forming surface of the mold.

[0015] Another subject of the invention is a method for forming and expanding sheets using the tools of the invention.

[0016] The disclosures made about this topic also apply to other topics, and vice versa. Topics disclosed in the context of one topic can be incorporated into other topics.

[0017] According to a preferred embodiment of the invention, for design changes and / or maintenance and / or repair / replacement of the formed and expanded sheet, only one, two, three, four or more, but not all, segments of the mold are changed, while the other segments remain usable. Preferably, each segment can be removed from the mold without removing adjacent segments.

[0018] Preferably, each segment is heated individually and / or in pairs. Preferably, each segment includes a temperature sensor whose signal is provided to a control system that controls the surface temperature of the segment in the mold. This allows control of the temperature of the forming surface of one, two, or three adjacent segments without affecting the temperature of other segments.

[0019] The forming and expanding tools and / or the methods of the present invention have the following advantages:

[0020] - Raw material blocks with a stand dimension can be used because only segments need to be produced instead of the entire mold.

[0021] - Large-sized molds can be produced using relatively small machines, such as milling machines.

[0022] For example, several milling machines can work simultaneously on the same mold, which is impossible with a single machine.

[0023] - Design changes can be easily made at the forming and expanding sheet without tipping over the entire mold.

[0024] - Damaged tools can be easily repaired by replacing sections instead of reworking the entire mold.

[0025] - The possibility of integrating heating as close as possible to the forming surface or mold.

[0026] - The mass of the mold can be reduced by hollowing out the rear of the useful shape (smaller mass = smaller inertia = less heat loss).

[0027] - An electric heater with higher efficiency than a hydraulic network (via an oil heater, etc.) can be used.

[0028] The lighter segments therefore reduce the mass of the moving parts and are easier to move, thus requiring less energy in production and for workers.

[0029] - Therefore, it is easier to integrate the insulation part, and thus reduce heat loss.

[0030] - The preparation time is reduced due to the reduced heating time.

[0031] - Control tool temperature more precisely by selecting the slice thickness of the segments. Attached Figure Description

[0032] The invention will now be further explained with reference to the accompanying drawings. These explanations also apply to all embodiments of the invention. These explanations do not limit the scope of protection of the invention.

[0033] Figure 1 The sheet material is shown.

[0034] Figure 2 The mold is shown.

[0035] Figure 3 The forming and expansion of the sheet under the influence of heat is shown.

[0036] Figures 4 to 6 Each of these embodiments of the tool of the present invention is illustrated. Detailed Implementation

[0037] Figure 1 A sheet shaped and expanded using the tool of the present invention is shown. The sheet 1 conventionally comprises at least one, preferably two, overlay layers 2 and an intermediate expandable layer, such as a polymeric material. The polymeric material is an expandable material that preferably expands under the influence of heat. During and / or after its expansion, the polymeric material is preferably cross-linked to provide rigidity.

[0038] Figure 2 A tool 14 for forming and expanding sheet 1 is shown. Tool 14 includes a first mold 4 and a second mold 5. Each mold 4, 5 provides a forming surface, which is a negative mold of the desired final shape of sheet 1. Preferably, the two molds can be moved relative to each other from a forming / expanding position to a remote position, and vice versa. In the forming / expanding position, sheet 1 is formed and expanded. In the remote position, sheet 1 can be removed from the tool. Figure 2 The image shows a location far from the viewpoint.

[0039] Figure 3 The expansion of sheet 1 is illustrated. After the molds 4, 5 move to their forming / expanding positions and / or during this process, the expandable layer 3 expands as indicated by double arrow 6, for example, by heating the sheet 1 through heat transfer from at least one mold 4, 5. This expansion provides the force to shape the sheet 1 into its desired form. In the forming and expanding positions, a gap initially exists that allows the sheet 1 to expand. This gap closes at least substantially after expansion is complete. Preferably, in its expanded state, the expandable layer cures, such that the shape of the sheet 1 is maintained and the sheet is mechanically stable.

[0040] Figure 4An embodiment of the tool of the invention is shown, wherein only the mold 5 is shown. As can be seen, the mold is divided into multiple, here five segments 8. Each segment extends the entire width of the mold and locally has the desired entire height. Together, the segments 8 provide a forming surface 15 for the sheet 1. In this case, the thickness of each segment is different, which is a preferred embodiment. By varying the thickness of each segment, local temperature control, mechanical stability, and / or reduced maintenance can be achieved, for example. Each segment is set, for example, by screws, preferably fixed to the frame 9. On the back side of the forming surface 15, material, preferably as much material as possible, is removed to reduce the thermal inertia of the segment. If necessary, for mechanical stability, a support member 7 may be provided between the segment and the frame. Two adjacent segments are connected to each other, preferably along the entire junction of the two adjacent segments, by connecting elements (preferably multiple connecting elements (e.g., screws)).

[0041] Figure 5 Segment 8 is shown with heating element 11, here an electric heating element, which is preferably individually controllable. The heating element is positioned near the forming surface 15 to allow precise temperature control of the surface and / or a short reaction time in the event of desired temperature changes on the forming surface. The heating element 11 is positioned in a groove within the contact area of ​​two adjacent segments and heats both segments simultaneously.

[0042] Figure 6 The heat insulation section between the frame 9 and the segment 8 of the mold 5 is shown, which reduces heat loss and / or reduces the thermal expansion of the frame.

[0043] List of reference numerals in the attached diagram:

[0044] 1. Sheet material, sandwich material sheet

[0045] 2 Covering layer

[0046] 3 expandable layers

[0047] 4. First mold

[0048] 5. Second mold

[0049] 6 Expansion

[0050] 7 Supporting Components

[0051] 8 segments

[0052] 9 frames

[0053] 10 connecting elements

[0054] 11 heating elements

[0055] 12 Isolation Sections

[0056] 13 slots

[0057] 14 Forming and Expanding Tools

[0058] 15 Formed Surface

Claims

1. A forming and expanding tool (14) having a first mold (4) and a second mold (5) and a space (15) between the first mold (4) and the second mold (5) for receiving a sheet (1) to be formed and expanded, characterized in that, The first mold (4) and / or the second mold (5) are provided by multiple segments (8).

2. The forming and expanding tool (14) according to claim 1, characterized in that, The segment (8) is connected to the frame (9).

3. The forming and expanding tool (14) according to claim 2, characterized in that, A heat insulation section is provided between the segment (8) and the frame (9).

4. The forming and expanding tool (14) according to any one of the preceding claims, characterized in that, The segments (8) are interconnected by connecting elements (10).

5. The forming and expanding tool (14) according to any one of the preceding claims, characterized in that, A heating element (11) is disposed adjacent to the forming surface of the mold (4, 5), preferably between two adjacent segments (8).

6. The forming and expanding tool (14) according to claim 5, characterized in that, The heating element (11) is arranged parallel to the forming surface (15) of the mold (4, 5).

7. The forming and expanding tool (14) according to claim 5 or 6, characterized in that, The heating element (11) is disposed in a groove (13) which extends parallel to and adjacent to the forming surface (15) of the mold (4, 5).

8. A method for forming and expanding sheet (1) using the tool (14) according to any one of claims 1 to 7.

9. The method according to claim 8, characterized in that, For design changes to formed and expanded sheets, only the segmentation of the mold needs to be changed.

10. The method according to claim 8 or 9, characterized in that, Each segment is heated individually and / or in pairs (8).

11. The method according to any one of claims 8 to 10, characterized in that, For maintenance or repair, only replace segment (8).

Images