Injection molding device for the production of a component

Abstract

Injection molding device (1) for producing a component (2), in particular a component (2) for a motor vehicle, by injection molding, wherein the injection molding device (1) is designed to introduce molten injection molding material through at least one outlet opening into at least one cavity (5) defining the shape of the component (2), wherein a material adjustment device (6) is designed to change a material composition, in particular a recycled content, of the injection molding material to be introduced into the cavity (5) during the production of a component (2).

Description

[0001] The invention relates to an injection molding device for manufacturing a component, in particular a component for a motor vehicle, by means of injection molding, wherein the injection molding device is designed to introduce molten injection molding material through at least one outlet opening into at least one cavity defining the shape of the component.

[0002] Injection molding devices for the production of components, for example, components for motor vehicles, in which molten injection molding material is introduced through at least one outlet opening into a cavity that defines the shape, i.e., the three-dimensional form, of the component, are generally known from the prior art. Furthermore, the prior art reveals efforts to use recycled material, i.e., reclaimed material, specifically recycled plastic material, in addition to virgin material. Recycled material therefore differs from virgin material in that it has been disposed of at least once and reused or "recycled" for the production of new products.For example, there are regulations that specify a recycled content in the production of new products, so that usually the injection molding material consists of a certain proportion of recycled material and only a remaining proportion of virgin material.

[0003] Especially in the production of automotive components that must meet high standards, particularly regarding surface quality, the use of recycled material is not always feasible. For example, impurities present in the recycled material can impair the quality of the components in a way that is unacceptable for achieving high quality standards. To nevertheless meet the requirements for a specific recycled content in the manufactured product, approaches exist in which a component is divided into several individual sub-components. The sub-components that are critical to the required quality are made from virgin material, while the less critical sub-components are made from recycled material. This ensures that the entire component meets both the quality requirements and the requirements for the use of recycled material.However, this often leads to a disproportionately high level of effort, as existing components must be redesigned or divided into the described sub-components, thus requiring a redesign of the tools, especially the cavities for the injection molding process. Furthermore, the individual sub-components are considerably more complex to produce, assemble, and adjust compared to a single-piece component.

[0004] The invention is based on the objective of providing an improved injection molding device in which quality requirements for the component can be met despite the use of recycled material.

[0005] The problem is solved by an injection molding device according to claim 1. The dependent claims relate to possible embodiments.

[0006] As described, the invention relates to an injection molding device designed for the production of a component, specifically a component for a motor vehicle, by injection molding. The device is designed to introduce molten injection molding material through at least one outlet opening into at least one cavity defining the shape of the component. In other words, the injection molding material can be melted by the device, for example, starting from a raw material, and introduced into the cavity through a plurality of outlet openings. The outlet openings can, in particular, be opened and closed in a controlled manner so that the molten injection molding material can be introduced into the cavity through the open outlet openings.

[0007] The invention is based on the finding that a material adjustment device is provided, in particular integrated into or connected to the injection molding machine, which is designed to change the material composition, in particular the recycled content, of the injection molding material to be introduced into the cavity during the production of a component. In other words, the injection molding machine is configured by means of the material adjustment device to change the material composition of the injection molding material during the manufacturing process. This means that while the injection molding material is introduced into the cavity to produce the component, the material composition is changed by means of the material adjustment device. As a result, the component is not produced with a uniform material composition, but rather has different material compositions in different areas.The material setting device can hold the injection molding material in various material compositions and supply them as needed, or create the material compositions as needed, for example by mixing different materials, such as virgin material and recycled material.

[0008] This also means that specific areas of the component can be selected to be manufactured with a particular material composition. For example, areas subject to particularly high quality requirements, such as visible surfaces, can be manufactured with one material composition, while areas with lower quality requirements can be manufactured with a second material composition.

[0009] For example, the first material composition can have a higher proportion of virgin material than the second, especially if it consists entirely of virgin material. Conversely, the second material composition can have a higher proportion of recycled material, for example, if it consists entirely of recycled material. Accordingly, the material compositions can be adjusted, specifically between 0% and 100% recycled material. Therefore, it is advantageously unnecessary to divide the component into individual sub-components manufactured with different material compositions to meet requirements regarding the use of recycled material. Instead, depending on which area of ​​the component is being manufactured by injecting the injection molding material, the appropriate recycled content or material composition is set and supplied by the material setting device.

[0010] The injection molding device can further be designed to include a material adjustment device configured to adjust the proportions of at least one material, particularly virgin material, and at least one material, particularly recycled material, in the injection molding material. As already described, the material composition can generally be adjusted between 0 and 100% virgin material and between 0 and 100% recycled material. The first material typically contains more virgin material than recycled material, and the second material contains a recycled material content that exceeds that of the first material. By way of example, the first material could be injection molding material with a material composition of 100% virgin material, and the second material could be injection molding material with a material composition of 75% virgin material and 25% recycled material. These numerical examples depend on the specific application and can be modified as needed.In other words, the material setting device precisely adjusts the amount of recycled material contained in the injection molding material used to produce a specific component area. This value can be changed during the production of the same component to manufacture different areas of the same component with different material compositions.

[0011] The injection molding device can be further developed such that the material setting device is configured to adjust the material composition of the injection molding material differently in at least two different areas of the same component, depending on a component parameter. As described, a quality parameter, such as a desired surface quality, can be used as the component parameter. Different areas of the component can thus be assigned to different classes or quality classes. A highest level can, for example, be designated as "A-area," in which only virgin material is used as injection molding material, i.e., a recycled content of 0. During component production, the component parameter can ultimately be used to set which material composition should be used in which areas of the component.to be injected into the section of the cavity assigned to the area for the formation of the area.

[0012] According to a further embodiment, the injection molding device can have a detection device, or a detection device can be associated with the injection molding device, which is configured to detect a flow front of the injection molding material in the cavity, wherein the material adjustment device is configured to adjust the material composition based on a detected flow front position. As described, the injection molding material is melted and introduced into the cavity through the at least one outlet opening. The flow front of the injection molding material in the cavity can be detected by the detection device, i.e., it can be determined to what extent the injection molding material has currently advanced into the cavity. This allows for a controlled feed of injection molding material into the cavity.Furthermore, the material composition can be adjusted by the material setting device in accordance with the current flow front position. In other words, defined material change points can be specified for the flow front position, from which the material composition of the injection molding material changes.

[0013] For example, a first section of the component can be produced with a first material composition of the injection molding material by introducing injection molding material with this first composition into the cavity until a first flow front position or material change point is reached within the cavity. From this point in the manufacturing process, the material setting device changes the current material composition of the injection molding material, namely from the first material composition to the second material composition intended for the second section of the component, which adjoins the first section.

[0014] In other words, once the first flow front position is reached, injection molding material with the second material composition is fed into the cavity to form the second area. A third area of ​​the component can then follow, requiring a third material composition. This third composition can differ from the first and second, or it can be the same as the first. When the injection molding material in the cavity reaches a second flow front position, the material feeder adjusts to the third material composition, allowing it to be fed into the cavity by the injection molding device to form the third area. Based on the procedure described above, any number of areas of the same component with different material compositions can be produced.For example, it is also possible to switch between available material compositions, so that, for example, a first area and a third area have the same material composition, which are separated from a second area that has a different material composition.

[0015] As previously described, multiple outlet openings, in particular a multitude of outlet openings, are provided, which are opened and closed in a coordinated manner to introduce injection molding material into the cavity. The opening of the outlet openings can be controlled, for example, depending on the current flow front position. In particular, in conjunction with the previously described flow front detection, at least one specific outlet opening can therefore be opened when a certain flow front position is reached, in order to introduce the necessary material composition for the corresponding area of ​​the component through the outlet opening.

[0016] In other words, the manufacturing process can be precisely controlled to ensure that the injection molding material with the required composition enters the cavity through the corresponding outlet. This enables an "in situ" reaction regarding the material composition of the injection molding material, depending on the current flow front position. The injection molding machine, specifically the detection unit, can incorporate suitable sensors to detect the flow front and its current position. While it is possible to detect the flow front over a specific time period, this can be inaccurate, particularly when using injection molding material with a high recycled content, as the properties of the recycled material, especially its flow velocity, may not be determined precisely enough.

[0017] The injection molding device may also be equipped with a detection device for time-controlled and / or temperature-controlled detection of the flow front. For example, several temperature sensors may be provided at the cavity to detect the point within the cavity to which the melt or the dispersed injection molding material has progressed. Since the melt typically has a significantly higher temperature, for example, >200 °C, than the mold or the cavity, which may be at room temperature, a comparatively precise location of the flow front is possible by measuring the temperature, for example, at an inner wall of the cavity.Therefore, if a first area of ​​the component has already been completely manufactured using injection molding material of the first material composition and the corresponding flow front position has been reached, which borders the first area from the second area, this can be detected in a time-controlled and / or temperature-controlled manner and the material composition can be changed accordingly by the material setting device, specifically to the second material composition that is required for the manufacture of the second area of ​​the component.

[0018] The injection molding device can further include at least two feeding devices for supplying injection molding material to at least two sections of a feed path, in particular a first material composition to a first section and a second material composition to a second section, wherein the at least two sections can be separated by at least one separating device. The different feeding devices can also be referred to as "multiple hoppers". For example, the injection molding device can have a screw as a feed path in which the injection molding material or the raw material is melted before being fed into the cavity.

[0019] The first feeding device can, for example, feed a first material composition into a first section of the feed path, and a second feeding device can feed a second material composition into a second section of the feed path. The first and second sections are separated, or can be separated, by a separating device, such as an aperture or iris diaphragm, thus preventing the different material compositions from mixing during melting. The material compositions can then be fed sequentially into the cavity. The separating device can be opened, for example, by opening the aperture, so that first the first material composition and then the second material composition are fed into the cavity one after the other.This ensures that the different material compositions are fed into the cavity in a pure form and that no mixing takes place.

[0020] According to a further embodiment, the injection molding device can be configured to produce a sequence of component areas, wherein the component area sequence comprises a sequence of a first component area of ​​a first component with a first material composition, at least a second component area of ​​the first component with a second material composition, a first component area of ​​a second component with the first material composition, and a second component area of ​​the second component with a second material composition. In principle, the component area sequence can therefore comprise any number of different components.

[0021] The components can be identical, meaning that they comprise the same component areas. To produce these identical components, a sequence of components is manufactured using the injection molding machine. As previously described, the material composition is changed for each component by the material adjustment device once the specific flow front position is reached, so that the first and second component areas are formed for each component by precisely feeding the first and second material compositions into the cavity.

[0022] The injection molding machine can be further developed to acquire or receive quality information, in particular surface quality, for at least one manufactured component and to adjust and / or change the material composition in at least one area, especially during a manufacturing process, based on this quality information. For example, at least one component produced with a specific material composition using the injection molding machine can be inspected. This inspection can include, for example, a visual inspection. The component can also be subjected to a temperature test, a humidity test, or a climate change test. Subsequently, a surface inspection can be performed to determine the surface quality or, more generally, the quality information.

[0023] If the component, or at least one inspected area, does not meet the specified quality requirements, the associated material composition can be changed. For example, the proportion of recycled material in this area can be reduced to meet the quality requirements. Similarly, if the surface finish is sufficiently ensured, the material composition can be changed incrementally and checked to ensure that the change still meets the quality specifications. This can be done, for example, by implementing the smallest possible increments to minimize scrap.

[0024] The material composition can be modified, for example, by increasing the recycled content, until a component or component section is produced that no longer meets the quality requirements. At least for a specific type of recycled material, a limit is then identified that must not be exceeded with regard to the recycled content. This allows, for example, the use of the highest possible recycled content without producing unacceptable effects on the quality information. In other words, the maximum recycled content that adequately fulfills the quality requirements can be determined.

[0025] In addition to the injection molding device, the invention relates to a method for manufacturing a component, in particular a component for a motor vehicle, by injection molding, wherein molten injection molding material is introduced through at least one outlet opening of an injection molding device into at least one cavity of the injection molding device defining the shape of the component, wherein a material composition, in particular a recycled content, of the injection molding material to be introduced into the cavity is changed during the manufacture of a component by means of a material adjustment device. The method can be carried out in particular with the injection molding device described above.

[0026] All advantages, details, designs and / or features described in relation to the injection molding device are fully transferable to the process.

[0027] The invention is explained with reference to exemplary embodiments and the figures. The figures are schematic representations and show: Fig. 1 a schematic representation of an injection molding device according to a first embodiment; Fig. 2 a schematic representation of an injection molding device according to a second embodiment; Fig. 3. A schematic representation of a manufacturing process for a component in a first process step; and Fig. 4 A schematic representation of a manufacturing process for a component in a second process step.

[0028] Fig. 1, Fig. Figure 2 shows an injection molding device 1 for the production of components 2 (see Figure 2). Fig. 3, Fig. 4) in two different embodiments. The basic structure of the injection molding device 1 is the same in both embodiments and is therefore described analogously. The injection molding device 1 is constructed in a manner known per se, for example comprising a feeding device 3 which is connected to a feed path 4, for example a screw which can be heated in order to melt injection molding material fed by the feeding device 3.

[0029] As is known, the injection molding device 1 is designed to introduce the injection molding material in molten form into a cavity 5. The cavity 5 defines the shape of the component 2, i.e., its three-dimensional form. The injection molding device 1 has a material adjustment device 6, which is fundamentally designed to adjust the material composition of the injection molding material while the material is being introduced into the cavity 5, or to adjust the material composition of the injection molding material so that injection molding material with the required material composition can be supplied to the cavity 5. In other words, this also changes the material composition of the component 2 throughout its manufacturing process.

[0030] The injection molding device 1 additionally has a detection device 7 which is designed to detect a flow front position 8 (cf. Fig. 3) to detect. The flow front position 8 indicates how far a flow front of the injection molding material being introduced into the cavity 5 has already progressed within the cavity 5. The detection device 7 can transmit the determined current flow front position 8 to the material setting device 6, so that the material setting device 6 can adjust the material composition of the injection molding material accordingly.

[0031] Fig. Figure 2 further shows that the injection molding device 1 can have not just a single feeder 3, but several, purely by way of example, three feeders 3, 3', 3" that are assigned to the same feed path 4. A separating device 9 is arranged between each of the feeders 3, 3', 3". The separating devices 9 divide the feed path 4 into different sections 10, 11, 12, into which the different material compositions are introduced by the feeders 3-3" . While the material is melted in the feed path 4, the separating devices 9 therefore spatially divide the feed path 4 into sections 10-12, thus preventing mixing.

[0032] If the injection molding material is subsequently fed from the feed path 4 to the cavity 5, the separating devices 9 can be opened so that the injection molding material can be fed sequentially and as unmixed as possible, and therefore in a pure form, to the cavity 5.

[0033] The injection molding device 1 specifically features a multitude of outlet openings (not shown) that can be opened and closed independently of one another. Depending on the determined or detected flow front position 8, the outlet openings can therefore be selectively opened to introduce the injection molding material into the cavity 5 at different positions.

[0034] Fig. Figure 3 shows a first process step or process state in an exemplary manufacturing process for producing a component 2. In the depicted first process step, the flow front position 8 is still within a first region 13 of the component 2, which is to be produced with a first material composition. In other words, the material setting device 6 initially sets the first material composition so that injection molding material with the first material composition is introduced into the cavity 5. By opening the outlet openings associated with the first region 13 accordingly, the injection molding material is directed into this region 13, and the first region 13 of the component 2 is formed.

[0035] When the flow front reaches the specific flow front position 8, which separates the first area 13 of component 2 from the second area 14 of component 2, this is detected by the detection device 7 and the material is fed accordingly to the material setting device 6. The material setting device 6 then sets the second material composition for the injection molding material required for the production of the second area 14. Accordingly, the material composition required for the formation of the different areas 13 and 14 is provided via the feeding device 3 or feeding devices 3-3" in such a way that the injection molding material has the respective required material compositions when it is introduced into the cavity 5. This is illustrated by example in Fig. Figure 4 shows that area 14 of component 2 is manufactured with the second material composition of the injection molding material. This allows, in particular, the one-piece formation of component 2 by injection molding with different material compositions in different areas 13, 14.

[0036] For example, area 13 may have higher quality requirements, and in particular, it may be classified as a so-called "A-area." This means that the highest quality requirements can apply to area 13, so that, for instance, the first material composition uses only virgin material or a reduced proportion of recycled material compared to the second material composition. Conversely, area 14, for example, has lower quality requirements, so that a higher proportion of recycled material can be used in the second material composition.

[0037] The individual material compositions can be defined arbitrarily. For example, a component 2 can be manufactured using the injection molding device 1 and inspected. A surface inspection can be performed, particularly after conditioning the component 2, specifically by means of a climate change test. If the surface inspection shows that the quality requirements have been met, further components 2 can be manufactured with the given material compositions.

[0038] If the inspection reveals that a quality criterion is not met, the material composition for the corresponding area 13, 14 can be changed, for example, by reducing the recycled content. It is also possible to modify the material composition, in particular by increasing the recycled content, until a component 2 or an area 13, 14 no longer meets the required quality standard. In other words, a maximum recycled content can be determined that yields satisfactory results. This allows, in particular, the use of recycled material to be maximized without any noticeable impact on the quality of component 2.

[0039] As described, the injection molding device 1, which is in Fig. 1-4, are trained to carry out the procedure described herein, or can perform the procedure, which is specifically related to Fig. 3, Fig. 4 was described, which relates to Fig. 1, Fig. The injection molding device 1 is described in section 2. The description of the injection molding device 1 is therefore fully transferable to the process and vice versa.

[0040] All advantages, details and features described in relation to the individual embodiments can be combined, interchanged and transferred to one another as desired. REFERENCE MARK LIST 1 injection molding device 2 components 3-3" feeder 4 Feed track 5-cavity 6 Material setting device 7. Recording device 8 Flow front position 9 Separating device Sections 10-12 Area 13, 14

Claims

[1] Injection molding device (1) for producing a component (2), in particular a component (2) for a motor vehicle, by injection molding, wherein the injection molding device (1) is designed to introduce molten injection molding material through at least one outlet opening into at least one cavity (5) defining the shape of the component (2), characterized by a material adjustment device (6) which is designed to change a material composition, in particular a recycled content, of the injection molding material to be introduced into the cavity (5) during the manufacture of a component (2). [2] Injection molding device (1) according to claim 1, characterized by , that the material adjustment device (6) is designed to adjust at least a material fraction of at least a first material, in particular virgin material, and at least a second material, in particular recycled material, to the injection molding material. [3] Injection molding device (1) according to claim 1 or 2, characterized by , that the material setting device (6) is designed to adjust the material composition of the injection molding material differently depending on a component parameter in at least two different areas (13, 14) of the same component (2). [4] Injection molding device (1) according to one of the preceding claims, characterized by a detection device (7) configured to detect a flow front of the injection molding material in the cavity (5), wherein the material setting device (6) is configured to adjust the material composition based on a detected flow front position (8). [5] Injection molding device (1) according to any one of the preceding claims, characterized by , that the injection molding device (1) is designed to open and / or close at least one outlet opening depending on the detected flow front position (8). [6] Injection molding device (1) according to claim 4 or 5, characterized by , that the detection device (7) is designed for time-controlled detection of the flow front and / or for temperature-controlled detection of the flow front. [7] Injection molding device (1) according to any one of the preceding claims, characterized by , that the injection molding device (1) has at least two feeding devices (3, 3', 3") for feeding injection molding material into at least two sections of a feed path (4), in particular a first material composition into a first section (10-12) and a second material composition into a second section (10-12), wherein the at least two sections are separable by at least one separating device (9). [8] Injection molding device (1) according to any one of the preceding claims, characterized by, that the injection molding device (1) is designed to produce a component area sequence, wherein the component area sequence comprises a sequence of a first component area (13) of a first component (2) with a first material composition and at least a second component area (14) of the first component (2) with a second material composition and a first component area (13) of a second component (2) with the first material composition and a second component area (14) of the second component (2) with a second material composition. [9] Injection molding device (1) according to any one of the preceding claims, characterized by, that the injection molding device (1) is designed to detect quality information, in particular surface quality, of at least one manufactured component (2) and to adjust and / or change the material composition in at least one area (13, 14), in particular during a manufacturing process, based on the quality information. [10] Method for manufacturing a component (2), in particular a component (2) for a motor vehicle, by injection molding, wherein molten injection molding material is introduced through at least one outlet opening of an injection molding device (1) into at least one cavity (5) of the injection molding device (1) defining the shape of the component (2), characterized by , that by means of a material adjustment device (6) a material composition, in particular a recycled content, of the injection molding material to be introduced into the cavity (5) is changed during the manufacture of a component (2).

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