Tool device for producing a composite component and method for producing a component from a composite material

Description

[0001] The invention relates to a tool device for producing a composite material component, comprising a molding tool with a contact area for a workpiece, wherein the molding tool is made of an electrically conductive material at least in a partial area, and an induction heating device with an inductive heating mat, wherein the heating mat is positioned at a distance from the molding tool, a positioning of the workpiece between the heating mat and the molding tool adjacent to the molding tool is provided, and a heating of the molding tool is provided at least in a partial area by the induction heating device.

[0002] The invention further relates to a method for producing a component from a composite material by means of a molding tool, in which a workpiece is placed against the molding tool at a contact area of the molding tool, and at least a partial area of the contact area of the molding tool is heated without contact by an inductive heating mat, wherein the workpiece is positioned between the contact area and the heating mat.

[0003] DE 10 2016 209 487 A1 discloses an induction heating device comprising at least one coil layer with a coil device and a carrier on which the coil device is arranged, wherein the at least one coil layer is designed to be flexible in bending and is embedded in the structural material of a vacuum hood and the vacuum hood with the at least one coil layer is designed to be flexible in bending.

[0004] US 2012 / 0018089 A1 discloses a molding device for producing parts from composite materials, wherein a deformable membrane is provided.

[0005] DE 10 2013 111 266 A1 describes a coil device comprising at least one current-carrying high-frequency stranded wire and a carrier for the at least one high-frequency stranded wire, wherein the at least one carrier is a mesh network and the at least one high-frequency stranded wire is held by one or more holding threads which rest on the at least one high-frequency stranded wire at webs of the mesh network.

[0006] From DE 10 2008 037 224 A1 a relaxation mat for transmitting vibrations generated by magnetic fields to organisms is known, which has at least one flat coil, above which permanent magnets are arranged flatly next to one another, intersecting the magnetic field of the flat coil.

[0007] From DE 101 55 935 A1 an intelligent label is known which comprises a textile carrier and a flexible wire- and / or thread-like electrical conductor, wherein the conductor is arranged on or in the textile carrier.

[0008] From DE 10 2011 106 648 A1 a portable data carrier with an antenna is known, wherein the antenna is produced by connecting longitudinal threads and transverse threads of an electrically conductive fabric.

[0009] From DE 10 2008 036 101 A1 an industrially manufactured textile material is known which has at least one electrically conductive structure in the form of at least one pattern.

[0010] From DE 32 05 048 A1 a magnetic coil is known which consists of flat, flexible conductor strands.

[0011] From DE 196 15 647 C2 a coil mat for generating a planar magnetic field is known.

[0012] DE 10 2011 076 463 A1 discloses a repair method for a molded part made of a plastic material. In this method, a repair element made of the plastic material is applied to a damaged area of the molded part and bonded to it by applying heat. The heat is generated by a passive heating element made of an electrically conductive material, which is exposed to an alternating magnetic field.

[0013] An induction heating coil is known from EP 0 271 250.

[0014] DE 10 2013 223 284 A1 discloses a device for producing a fiber-reinforced plastic component, comprising a forming tool in which a plate-like, in particular textile, semi-finished fiber product is hot-formed, in which electrically conductive reinforcing fibers are embedded in a heat-activatable binder, and an induction heater comprising at least one inductor for generating an alternating magnetic field that induces electrical currents in the electrically conductive reinforcing fibers of the semi-finished fiber product. The inductor is at least one flat insert separate from the forming tool and insertable into the forming tool together with the semi-finished fiber product.

[0015] From EP 2 508 329 A1 a composite material consolidation device for inductively heating and consolidating a composite material is known.

[0016] From DE 10 2015 114 880 A1 an inductively heatable molding tool is known, comprising an inductor holder and a susceptor serving as a receiver of the alternating electromagnetic field generated by an inductor, wherein the inductor holder allows different laying patterns of the inductor.

[0017] From DE 10 2019 109 136 A1 a device for producing near-net-shape, three-dimensional preforms is known, comprising a three-dimensional base body for a deposition process of at least one provided pretreated tape or of at least one provided product which comprises at least one pretreated tape, wherein the tape comprises at least one matrix system and at least one fiber.

[0018] From DE 20 2015 100 080 U1 an induction heating device is known, comprising a carrier and a coil device which is arranged on the carrier.

[0019] From US 5,683,608 A a press-form element for use in an induction heating device is known.

[0020] The invention is based on the object of providing a tool device of the type mentioned at the outset with which composite material components can be produced in a simple manner.

[0021] This object is achieved according to the invention in the tool device mentioned at the outset in that a stamp is provided as a counter element for the molding tool, wherein the heating mat is integrated into the stamp.

[0022] At least in the part of the mold made of the electrically conductive material, the inductive heating mat can be used to induce eddy currents and the corresponding eddy current losses. The induction heating device thus allows the mold to be heated contactlessly.

[0023] The mold doesn't need to be specially designed for this. For example, it doesn't require the integration of heating cartridges or anything similar.

[0024] The induction heating device allows heating to be carried out close to the surface of the forming tool and thus in a contact area for the workpiece.

[0025] The electrically conductive material has, in particular, an electrical conductivity (at 25°C) of at least 10 3 S / m, preferably at least 10 4 S / m, preferably at least 10 5 S / m, and preferably at least 0.5 10 6 S / m (metallic electrical conductivity). It is a metal or other material with corresponding electrical conductivity, such as graphite, or, for example, provided with conductive fibers.

[0026] In one embodiment, the mold is made entirely of the electrically conductive material, or it has a partial region made of the electrically conductive material, which is arranged and configured such that the workpiece can be heated by heating this partial region by the induction heating device. In particular, this partial region is arranged or formed at the contact area for the workpiece. The workpiece can then be heated contactlessly via the inductive heating mat using eddy current heating.

[0027] It can be provided that the partial area is formed from a layer of electrically conductive material that is firmly connected to a support area of the mold or is placed on the support area. By using such a layer of electrically conductive material, induction heating can be achieved even if the rest of the mold is not made of an electrically conductive material. The corresponding eddy currents are then concentrated on this layer.

[0028] In one embodiment, the layer of electrically conductive material is a coating on the mold. This coating is produced, for example, by electroplating.

[0029] It is advantageous if the heating mat is adapted to the shape of the component to be manufactured. This results in optimized component production from a single workpiece.

[0030] In one embodiment, the induction heating device has an ohmic heating function, and in particular, the workpiece can also be heated directly via the induction heating device. For example, if the heating mat (with a coil arrangement) is operated in such a way that relatively large ohmic losses occur, then ohmic heating of the heating mat also occurs. This can be used in addition to applying heat to the workpiece. For example, it is possible to apply heat to the workpiece from the side of the forming tool and also from the side of the induction mat.

[0031] In one embodiment, at least one susceptor is positioned between the workpiece and the heating mat, wherein the at least one susceptor is permeable to electromagnetic fields of the heating mat such that the mold can be heated by the heating mat, and the susceptor can be heated, in particular inductively, by the heating mat. This allows the workpiece to be additionally exposed to heat from the side of the heating mat. The susceptor is designed, for example, as a metal foil. It is permeable to electromagnetic fields such that eddy currents can be induced in the mold by a magnetic field of the inductive heating mat. Furthermore, eddy currents can be induced in the susceptor, so that the susceptor is heated inductively.

[0032] A stamp serves as a counter element for the mold, with the heating mat integrated into the stamp. This allows for optimized molding.

[0033] In one embodiment, the inductive heating mat is a mat with a coil device. This can induce magnetic fields that induce alternating currents. The coil device can be arranged on the mat without a support (and in particular, form it), or it can be arranged on a support.

[0034] It is advantageous if the inductive heating mat is at least one of the following: flexible; elastic; pliable; dimensionally stable; dimensionally stable and deformable.

[0035] This results in optimized adaptability and, in particular, allows components of a given geometry to be manufactured. A flexible inductive heating mat, for example, can be advantageous if it is to be placed on a workpiece with a specific shape and is to adapt to it. A dimensionally stable design can be advantageous if, for example, a punch is provided as a counter-element to the forming tool. A dimensionally stable deformability or a dimensionally stable yet flexible design can be provided in order to bring the inductive heating mat into a specific shape that is then retained.

[0036] Inductive heating mats are described, for example, in DE 20 2015 100 080 U1 or in the unpublished German utility model application No. 20 2018 103 385.9 of June 15, 2018, filed by the same applicant. These documents are expressly incorporated by reference.

[0037] The heating mat includes a coil device.

[0038] In one embodiment, the heating mat comprises a coil device with a plurality of spiral windings arranged in rows and columns. In particular, the spiral windings are configured such that, when current flows through the spiral windings, the current direction in adjacent edge winding sections of adjacent spiral windings in a row or column is at least approximately the same.

[0039] The appropriate design of the spiral windings ensures that there is no mutual cancellation of electromagnetic fields in the intermediate region between adjacent spiral windings. The geometric arrangement of the turns of the spiral windings, through the appropriate arrangement and design of the edge winding sections, ensures that in this intermediate region, the current flows in the same direction through adjacent spiral windings, thus preventing field attenuation.

[0040] An edge winding section is a section of an outer turn.

[0041] For example, providing a single spiral winding results in a highly inhomogeneous energy density distribution. By providing a plurality of spiral windings with the inventive design, a homogenized energy density distribution is achieved during operation when current flows, which in turn enables homogeneous heating of components.

[0042] In relation to the surface of the carrier on which spiral windings are arranged, homogeneous heating can be achieved.

[0043] The spiral windings on the carrier form islands, so to speak, whereby the islands are wound in such a way that field cancellation in the intermediate region between adjacent spiral windings is avoided.

[0044] In principle, the corresponding induction heating device can be expanded as required in terms of area.

[0045] In particular, it is provided that a first spiral winding has a first edge winding section and a second spiral winding has a second edge winding section, wherein the first spiral winding and the second spiral winding are adjacent, and wherein the first edge winding section and the second edge winding section are adjacent, and wherein, during current flow, the current direction in the first edge winding section and the second edge winding section is at least approximately the same. This prevents field cancellation in the intermediate region between the adjacent first spiral winding and the second spiral winding. This, in turn, enables homogeneous heating of a component that is heated with the corresponding induction heating device.

[0046] For the same reason, it is advantageous if the current flow in adjacent edge winding sections of adjacent spiral windings in both a row and a column is at least approximately the same. This prevents field cancellation in the intermediate regions between adjacent spiral windings on a two-dimensional surface.

[0047] It may be provided that adjacent spiral windings are spaced apart or overlap each other, depending on the application.

[0048] If adjacent spiral windings are spaced apart, then corresponding adjacent edge winding sections are also spaced apart. If adjacent spiral windings overlap, then adjacent edge winding sections can be arranged to intersect in a projection onto the carrier.

[0049] For a homogeneous energy density distribution, it is advantageous if the spiral windings are arranged in a two-dimensional grid on the substrate with respect to the columns and rows. This allows for a homogeneous coverage of the substrate, which in turn enables a homogeneous energy density distribution.

[0050] It is particularly advantageous if the grid is a rectangular grid and advantageously a square grid in order to achieve a homogeneous energy density distribution and thus homogeneous heatability of a component.

[0051] It is advantageous if spiral windings of at least one type are designed identically with respect to an outer envelope. This allows for a high degree of homogeneity.

[0052] For the same reason, it is advantageous if spiral windings of at least one type are designed to be identical in terms of the number of turns.

[0053] It has proven advantageous if a spiral winding has at least two turns and in particular at least three turns.

[0054] It has also proven advantageous to achieve uniform heating if a spiral winding has a maximum of eight turns and in particular a maximum of seven turns.

[0055] It is advantageous if the coil device comprises a first type of spiral winding, in which turns run outward from an output point with increasing distance from the output point, and a second type, in which turns run from outside to inside towards an output point with decreasing distance from the output point. The corresponding direction (outward or inward) can be related to the current flow. By providing two different types of spiral windings, it is easy to ensure that the current flow in edge winding sections of adjacent spiral windings has approximately the same direction.

[0056] It is particularly advantageous if spiral windings of the first type and the second type are arranged alternately in the rows and columns. This makes it easy to ensure that the edge winding sections of adjacent spiral windings carry a current with at least approximately the same current direction in both the rows and columns. This, in turn, prevents field cancellation in the corresponding areas.

[0057] Advantageously, the direction of rotation of an electric current within a spiral winding is the same, while the directions of rotation in neighboring spiral windings are opposite. This makes it easy to ensure that adjacent edge winding sections of adjacent spiral windings carry currents whose direction is at least approximately the same.

[0058] A spiral winding is characterized by the fact that the distance increases or decreases from a point (starting point) or an axis. In principle, this increase or decrease can be monotonic. It is also possible for the corresponding spiral winding to be formed over at least approximately straight winding sections. As a result, the increase or decrease is not monotonic, but rather an increase or decrease occurs only in certain sections. Such a spiral winding with straight winding sections can be manufactured easily.

[0059] It is advantageous if adjacent edge winding sections of adjacent spiral windings are oriented at least approximately parallel to each other. This makes it easy to ensure that the current direction in these adjacent edge winding sections is at least approximately the same.

[0060] It is provided that a plurality of spiral windings are electrically connected in series. In particular, adjacent spiral windings are electrically connected in series. This makes it easy to ensure that the current flow in adjacent edge winding sections has the same current direction.

[0061] For example, the spiral windings in a row or column are electrically connected in series, and correspondingly, rows or columns of spiral windings are electrically connected in series. This results in a meandering current flow with respect to the main current direction.

[0062] It can be provided that an electrical connection between adjacent spiral windings within a row or column is established via edge winding sections, or via a connection between the starting points for turns of a spiral winding. This makes it possible to connect spiral windings with an "inward orientation" and an "outward orientation." This, in turn, enables different directions of rotation for the current flow within adjacent spiral windings. This, in turn, makes it easy to realize at least approximately the same current direction in adjacent edge winding sections of adjacent spiral windings.

[0063] In particular, within a row or column, the electrical connection between edge winding sections and output points is alternating. This allows for an alternating direction of rotation of the current, thus achieving a homogeneous energy density.

[0064] Advantageously, an electrical connection between adjacent rows or columns is established via an edge winding section and an exit point for turns of adjacent spiral windings. This allows for a simple electrical connection between adjacent rows or columns.

[0065] It is advantageous if the coil device comprises one or more flat coils. This allows a surface induction heating device to be easily implemented.

[0066] In one embodiment, the coil device is formed by at least one high-frequency stranded wire. This allows a coil device to be easily implemented that is arranged on a carrier.

[0067] It is advantageous if the at least one high-frequency strand is held to a carrier via one or more retaining threads. The at least one high-frequency strand can thus be easily fixed to the carrier in the appropriate shape. This allows for the creation of a flexible carrier with a flexible high-frequency strand. An induction heating device can be realized, particularly as a surface heating device, which is flexible in bending. This allows, for example, curved components to be heated, or a corresponding heating mat can be integrated into a curved tool.

[0068] In particular, it is provided that the carrier is a mesh network, and the at least one high-frequency stranded wire is sewn to the mesh network. This allows a high-frequency stranded wire to be easily connected to the carrier in a defined geometric position with the spiral windings.

[0069] According to the invention, a method for producing a component from a composite material by means of a molding tool is provided, in which a workpiece is placed on the molding tool at a contact area of the molding tool, and at least a partial area of the contact area of the molding tool is heated without contact by an inductive heating mat, wherein the workpiece is positioned between the contact area and the heating mat, and wherein a stamp is used as a counter element for the molding tool, wherein the heating mat is integrated into the stamp.

[0070] The method according to the invention has the advantages already explained in connection with the tool device according to the invention.

[0071] Further advantageous embodiments of the method according to the invention have already been explained in connection with the tool device according to the invention.

[0072] In particular, the method according to the invention can be carried out on the tool device according to the invention, or the tool device according to the invention can be operated with the method according to the invention.

[0073] It is advantageous if the heating mat itself is heated by ohmic heat and the workpiece is heated via ohmic heat. This allows the workpiece to be heated from two sides, namely from the side of the mold and from the side of the heating mat. Alternatively or additionally, it is advantageous to position a susceptor between the heating mat and the workpiece. This susceptor is permeable to the electromagnetic fields of the heating mat in such a way that the mold is heated by the heating mat (inductively) and the susceptor is heated by the heating mat (especially inductively). This also allows the workpiece to be heated from the side of the heating mat.

[0074] It is particularly advantageous if the heating mat is adapted or adaptable to a workpiece shape, and in particular to the shape of a component to be manufactured. This opens up a wide range of possible applications. The following description of preferred embodiments, in conjunction with the drawings, serves to explain the invention in more detail. They show: Figure 1 shows a schematic representation of an example of a tool device for producing a composite component; Figure 2 shows a plan view of an embodiment of a heating mat of an induction heating device; Figure 3 shows a schematic representation of an embodiment of an induction heating device with a coil device of the heating mat according to Figure 2; Figure 4 shows a schematic representation of a further example of a tool device; Figure 5 shows a schematic representation of a further example of a tool device; and Figure 6 shows a schematic representation of an embodiment of a tool device according to the invention.

[0075] An example of a tool fixture used in Figure 1 shown schematically and designated 10, comprises a forming tool 12. The forming tool 12 has a contact area 14 for a workpiece 16. A composite component such as a fiber composite component is produced from the workpiece 16.

[0076] The shape of the contact area 14 is adapted to a component to be manufactured. Figure 1 the contact area 14 is shown in a curved shape.

[0077] In one embodiment, the molding tool 12 is made of an electrically conductive material, such as a metallic material, and in particular, is made entirely of a metallic material. The material may, for example, also be non-metallic and comprise electrically conductive fibers, such as carbon fibers, to provide an electrical conductivity of, in particular, at least 10 4 S / m and preferably at least 0.5 10 6 S / m.

[0078] An induction heating device 18 is provided. This comprises an inductive heating mat 20 and a high-frequency source device 22.

[0079] Embodiments of an induction heating device 18 and in particular of an inductive heating mat 20 are described in more detail below.

[0080] The workpiece 16 is placed against the contact area 14 of the forming tool 12. The workpiece 16 is positioned between the inductive heating mat 20 and the forming tool 12; the inductive heating mat 20 is spaced apart from the forming tool 12 and thus also spaced apart from the contact area 14 of the forming tool 12.

[0081] To produce a component from a composite material, a structure of prepreg layers, for example, is used as the workpiece 16. These are fabric layers impregnated with resin. The resin can be cured by heating the workpiece 16.

[0082] According to the invention, the molding tool 12 is heated contactlessly via the inductive heating mat 20. When the inductive heating mat 20 is appropriately supplied with an alternating current, it heats a heating region 24 of the molding tool 12. This heating region 24 is located in particular at the contact area 14. When a corresponding alternating current flows through the inductive heating mat 20, it generates an alternating magnetic field, which generates eddy currents in the molding tool 12 and, in particular, in the heating region 24. The eddy current losses lead to heating at the heating region 24 and thus at the contact area 14. This, in turn, allows the workpiece 16, which rests against the contact area 14, to be heated.

[0083] The inductive heating mat 20 heats the tool 12 at a distance from the latter in the heating area 24.

[0084] It can also be provided that the current flow in the inductive heating mat 20 heats it due to ohmic losses. If the heating mat 20 rests on the workpiece 16 or is connected to the workpiece 16 via a heat-conducting layer, the workpiece 16 can also be heated directly via the heating mat 20. In such an embodiment, the workpiece 16 is heated from two sides, namely from the heating area 24 (where the eddy currents there are caused by the inductive heating mat 20), and from ohmic heating of the inductive heating mat 20 on an opposite side.

[0085] An embodiment of an induction heating device, which is shown in Figure 2 is shown in a plan view and is designated there by 110, comprises a carrier 112. This carrier 112 is designed as a mesh network.

[0086] The corresponding induction heating device is described in DE 20 2015 100 080 U1. Reference is made to this document in its entirety.

[0087] The mesh 112 is, for example, a textile structure, such as a woven or knitted fabric.

[0088] The mesh network 112 comprises meshes with webs, which are particularly rectangular or square. The webs are made, for example, from a thread material.

[0089] The support 112 with the mesh net is bendable as a whole.

[0090] A coil device 114 is arranged on the carrier 112. The coil device is formed by a current-carrying high-frequency stranded wire 116. This forms an inductive heating mat 115 corresponding to the heating mat 20.

[0091] The high-frequency stranded wire 116 is used to carry a high-frequency alternating current. The high-frequency stranded wire 116 is a bundle of individual wires, each of which is electrically insulated from one another. This effectively increases the cross-section involved in the current flow compared to a solid wire, while reducing the influence of the skin effect. Furthermore, the displacement of charge carriers to one side of the corresponding conductor by the magnetic field of a coil made from it is reduced (proximity effect).

[0092] In one embodiment, the wire bundle is arranged in a sheath 118, which is in particular multi-layered.

[0093] For further details on the design of the high-frequency strand 116, please refer to DE 10 2013 111 266 A1. This document is expressly incorporated by reference in its entirety.

[0094] The coil device 114 is a high frequency source device 120 (see Figure 3 ). The individual wires of the wire bundle of the high-frequency strand 116 are electrically connected to corresponding terminals 122a, 122b of the high-frequency source device 120 during operation of the induction heating device 110.

[0095] For this purpose, the high-frequency stranded wire 116 has a terminal 124 at a first end and a terminal 126 at a second end.

[0096] The high-frequency source device 120 serves to generate a high-frequency electromagnetic alternating field, which is applied to the high-frequency stranded wire 116. The frequency is at least 20 kHz and is typically approximately 150 kHz.

[0097] The high frequency source device 120 comprises an electronic switching device for generating the corresponding alternating field when the primary electrical source is a direct current source.

[0098] The high-frequency stranded wire 116 is a linearly bending flexible cable.

[0099] The coil device 114 comprises a plurality of spiral windings 128. These spiral windings 128 are arranged on the carrier 112 in rows 130 and columns 132. To form a surface induction heating device 110, the spiral windings 128 are evenly distributed on the carrier 112. The spiral windings 128 are formed on the high-frequency stranded wire 116.

[0100] In particular, the spiral windings 128 are arranged in a two-dimensional grid by the rows 130 and columns 132 on the carrier 112. This two-dimensional grid is in particular a rectangular grid and preferably a square grid.

[0101] Each spiral winding 128 has a plurality of turns 134, which are referenced to a starting point 136. An starting point 136 lies on a winding axis of the turns 134 of the spiral winding 128. The winding axis is oriented perpendicular to the carrier 112. The spiral of a spiral winding 128 is defined as a curve that moves away from or approaches the starting point 136 or the winding axis, respectively. The distance can be monotonically increasing, or the approach can be monotonically decreasing, or it can be increasing or decreasing in sections.

[0102] The arrangement of the spiral windings 128 on the carrier 112 determines the temperature distribution on an object to be heated.

[0103] The coil device 114 is designed so that over the surface of the coil device 114a homogeneous field distribution is achieved and, in particular in the area between adjacent spiral windings 128, a "field cancellation" of the generated magnetic fields is avoided.

[0104] When current flows through a spiral winding 128, the direction of rotation of the current flowing through it is the same within a spiral winding 128. According to the invention, the direction of rotation for the current flow in adjacent spiral windings 138a, 138b and 140a, 140b is opposite for both rows 130 and columns 132. This avoids the described cancellation of the electromagnetic field.

[0105] The spiral windings 128 of the coil device 114 are electrically connected in series. In the embodiment shown ( Figures 2 , 3), the spiral windings 128 are connected in series in a row 130. The corresponding rows 130 are in turn connected in series.

[0106] The coil device 114 comprises two types of spiral windings 128, namely a first type in which corresponding turns 134 extend from the respective starting point 136 outwards with increasing distance (at least in sections) from the starting point 136. In Figure 3 The spiral windings 138a and 140a are of the first type.

[0107] In the spiral windings 128 of a second type, the corresponding turns 134 run to the starting point 136 from the outside to the inside with decreasing distance (at least in sections) from the starting point 136. In the embodiment according to Figure 3 the spiral windings 138b and 140b are of the second type.

[0108] The corresponding winding direction of the first type and the second type is related to the corresponding current flow.

[0109] In a row 130, the spiral windings 128 of the first type and second type are arranged alternately.

[0110] Within a column 132, the spiral windings 128 of the first type and second type are also arranged alternately.

[0111] This results in an alternating opposite direction of rotation of the current both within a row 130 and within a column 132 with respect to adjacent spiral windings 128 when current flows.

[0112] The respective spiral windings 128 have edge winding portions adjacent to adjacent spiral windings. For example, spiral winding 138a has an edge winding portion 142a adjacent to a corresponding edge winding portion 142b of spiral winding 138b.

[0113] The edge winding sections 142a and 142b are arranged such that when current flows through the coil device 114, the current direction in them is at least approximately the same.

[0114] This prevents the resulting electromagnetic fields from being "cancelled" in the corresponding area.

[0115] Accordingly, edge winding sections 144a, 144b of spiral windings 140a, 140b adjacent in a column 132 are arranged such that the current flow in them occurs at least approximately in the same direction.

[0116] The arrangement of the edge winding sections 142a, 142b, 144a, 144b is achieved by corresponding arrangement of spiral windings 128 of the first type and the second type, which is alternating in both the rows 130 and the columns 132.

[0117] To establish the series connection of the spiral winding 128, adjacent spiral windings 128 are electrically connected within a row 130. Within a row 130, a first connection type 146 is provided, in which output points 136 of adjacent spiral windings 128 are connected to one another (by a corresponding section 148 of the high-frequency stranded wire 116).

[0118] In a second connection type 150, the connection between adjacent spiral windings 128 is made via an edge winding section 152.

[0119] Within a row 130, the first connection type 146 and the second connection type 150 alternate between adjacent spiral windings 8.

[0120] A third electrical connection type 154 is provided for electrical connection between adjacent rows 130. This type of connection establishes an electrical connection between an output point 136 and an edge winding section 156.

[0121] The spiral windings 128 are arranged as flat coils on the carrier 112 by appropriately "laying" the high-frequency stranded wire 116.

[0122] In one embodiment, the spiral windings 128 ( Figures 2 , 3) straight sections 158. As a result, the spiral winding 128 is not one that moves away from the corresponding starting point 136 in a monotonically increasing manner or approaches it in a monotonically decreasing manner. However, with respect to these sections, there is a section-by-section movement away from or approaching the corresponding starting point 136.

[0123] In the exemplary embodiment of spiral windings 128 with straight sections 158, adjacent edge winding sections 142a, 142b and 144a, 144b are preferably oriented parallel to one another. This results in a parallel current direction there.

[0124] It is in principle possible for adjacent spiral windings to be spaced apart from each other and for their corresponding adjacent edge winding sections to be spaced apart from each other.

[0125] The spiral windings 128 according to the embodiment of the Figures 2 , 3 are arranged like this.

[0126] It is also possible for adjacent spiral windings to overlap, resulting in stacked turns. (The high-frequency stranded wire 116 is insulated from the outside.)

[0127] It is possible that edge winding sections which are adjacent cross each other (in the projection onto the carrier 112).

[0128] Each spiral winding 128 of the coil device 114 has a plurality of turns 134. Preferably, each spiral winding 128 has at least two and preferably at least three turns 134. It is further advantageous if each spiral winding 128 has at most eight and preferably at most seven turns 134.

[0129] In principle, it is advantageous if the spiral windings 128 of at least the same type are designed identically with regard to the number of turns and the outer envelope area.

[0130] The mesh network has a first side 168 and a second side opposite the first side. The high-frequency strand 116 is preferably arranged exclusively or largely on the first side 168.

[0131] The corresponding winding axes of the spiral windings 128 are transverse and in particular perpendicular to the carrier 112.

[0132] The high-frequency stranded wire 116 is fixed to the carrier 112 via one or more holding threads 170 and, in particular, is sewn thereto. This fixation via holding threads 170 also creates the winding structure of the coil device 114 on the carrier 112.

[0133] With regard to the fixation of the coil device 114 to the mesh of the carrier 112 via holding threads 170, reference is made to DE 10 2013 111 266 A1.

[0134] It can be provided that the coil device 114 is assigned a magnetic flux concentrator layer, which is arranged in particular on the side of the carrier 112 facing away from the first side 168. Such a magnetic flux concentrator layer, which is made of a material with corresponding magnetic permeability, serves to concentrate the magnetic flux generated during operation of the coil device 114 in a foreground in front of the first side 168.

[0135] Furthermore, outer electrical insulating layers can be provided, between which the carrier 112 with the coil device 114 fixed thereto and, if applicable, the magnetic flux concentrator layer are arranged. Such outer electrical insulating layers are made, for example, of a silicone material.

[0136] The outer electrical insulation layers or the magnetic flux concentrator layer are designed to be flexible.

[0137] The carrier 112 is flexible. The high-frequency stranded wire 116 is bendable with the carrier 112. The connection of the high-frequency stranded wire 116 to the carrier 112 via the holding thread(s) 170 enables the bendability. The carrier 112 with the coil device 114 forms a flexible heating mat 172.

[0138] The induction heating device 110 can be formed into various geometric shapes. For example, a single curvature or multiple curvatures are possible.

[0139] The induction heating device is designed as a surface induction heating device, in which the arrangement of the spiral windings 128 avoids areas with mutually canceling electromagnetic fields. This allows for homogeneous heating with high flexibility.

[0140] The spiral windings 128 on the carrier 112 form field-generating islands. By appropriately shaping the islands, the "heating surface" can be expanded or adjusted to any desired size. This is then achieved by appropriately "laying" the high-frequency stranded wire 116 on the carrier 112.

[0141] It is also possible for the induction heating device to comprise, as a heating mat, a coil device with a plurality of spiral windings arranged in rows and / or columns, wherein the at least one coil device is formed by a tube through which a heat transfer medium can flow.

[0142] The tube can be mounted on a support, or a support-free heating mat, particularly a flexible (or dimensionally stable flexible) heating mat, can be formed by the tube. In this context, reference is made to German utility model application No. 20 2018 103 385.9, filed on June 15, 2018, by the same applicant.

[0143] It is fundamentally possible for the corresponding inductive heating mat 20 to be dimensionally stable. The dimensional stability can be permanent or variable. For example, if the coil device is formed by a tube, the corresponding heating mat can be easily designed to be dimensionally stable.

[0144] The heating mat can be designed to be flexible or bendable. It can be designed to be flexible, or it can be designed to be flexible in the manner of plastic deformability. For example, if the support 112 is designed accordingly, a flexible design can be achieved. In this sense, the heating mat 20 can also be designed to be flexible yet dimensionally stable.

[0145] Another example of a tool device, which is shown schematically in Figure 4 is shown schematically, is basically constructed in the same way as the tool device 10 with forming tool 12 and inductive heating mat 20.

[0146] In this embodiment, at least one susceptor 26 is provided, which is positioned between the inductive heating mat 20 and the mold 12, and thereby the contact area 14. The susceptor 26 forms a corresponding intermediate layer between the inductive heating mat 20 and the workpiece 16.

[0147] The (at least one) susceptor 26 serves to support the heating process. The susceptor 26 is designed, for example, as a metal sheet or metal foil. It is also adapted accordingly to the shape of the workpiece or the component to be manufactured.

[0148] The susceptor 26 is designed such that it is permeable to the electromagnetic fields of the inductive heating mat 20, allowing the inductive heating mat 20 to inductively heat the corresponding heating area 24 on the mold 12. Furthermore, the susceptor 26 is designed such that eddy currents can also be induced therein, resulting in eddy current losses and thus allowing the workpiece 16 to be inductively heated from the side of the inductive heating mat 20 via the susceptor 26.

[0149] The inductive heating mat 20 thereby inductively heats the susceptor 26 and the mold 12. In addition, with an appropriate setting of an operating point, the susceptor 26 can also be heated by ohmic losses via the inductive heating mat 20.

[0150] In another example of a tool device, which is shown in Figure 5 Shown schematically and designated 28, a molding tool 30 made of an electrically non-conductive material, such as a non-metallic material, is provided. A layer 32 made of an electrically conductive material, such as a metallic material, is arranged on the molding tool 30. In one embodiment, this layer 32 is a coating made of a metallic material, which is applied to a carrier region 34 of the molding tool 30. For example, a corresponding metallic layer is galvanically deposited on the carrier region 34.

[0151] In an alternative embodiment, the layer 32 of electrically conductive material is applied to the mold 30; for example, it is applied as a metallic foil.

[0152] The workpiece 16 is positioned on the layer 32. The layer 32 thus forms the contact area 14 of the forming tool 30.

[0153] An inductive heating mat 20 is spaced apart from the forming tool 30 including the layer 32 as described above, ie the heating mat 20 is spaced apart from the layer 32. The workpiece 16 is positioned between the inductive heating mat 20 and the layer 32.

[0154] The inductive heating mat 20 generates eddy currents in layer 32 of electrically conductive material. No eddy currents are generated in the mold 30 outside layer 32.

[0155] Layer 32 thus forms heating area 24.

[0156] Otherwise, the tool device 28 functions as described above with reference to the tool device 10. In particular, one or more susceptor layers can also be used in the tool device 28.

[0157] An embodiment of a tool device according to the invention, which is shown in Figure 6 The tool device shown in FIG. 1 is fundamentally identical in design to the tool device 10. The same reference numerals are used for identical elements. A punch 36 is provided as a counter-element to the corresponding forming tool 12. The forming tool 12 can be used to form the workpiece 16 on a first side 38. It can be formed on a second, opposite side 40 using the punch 36.

[0158] The inductive heating mat 20 is integrated into the punch 36 or is part of the punch. Preferably, the punch 36 is then not made of a metallic material or is made of metallic material in an area with a sufficiently large distance from the inductive heating mat 20. According to the invention, a tool device is provided in which a heating area 24 is heated, against which a workpiece 16 rests. The heating area 24 is heated by inductive heating via eddy current losses via an inductive heating mat 20.

[0159] In this way, for example, an existing mold 12 can be subsequently heated without having to integrate heating cartridges or the like into it.

[0160] Components made of composite materials can be manufactured on a corresponding tool device 10 without the need to use an autoclave.

[0161] In particular, flat components can be produced on a forming tool 12.

[0162] By using an inductive heating mat 20, a high degree of flexibility in shaping can be achieved. The inductive heating of the heating area 24 ensures that heat from the heat source reaches the component to be heated not only via thermal conduction.

[0163] The molding tool 12 can be designed independently of the heating system, since contactless heating is provided via the spaced-apart inductive heating mat 20. Subsequent use of induction heating technology for a molding tool 12 is possible.

[0164] Near-surface heating is possible.

[0165] For example, moving workpieces 16 can also be heated up in a simple manner.

[0166] The inductive heating mat 20 allows local and near-surface heating of the mold 12 to be achieved, adapted to the size of a component to be produced.

[0167] If the inductive heating mat 20 is operated at a corresponding operating point, a workpiece 16 can also be heated via an ohmic resistance on the inductive heating mat 20 and a corresponding ohmic heat.

[0168] The component to be manufactured can be entirely made of composite material, or it can also be a component that contains a composite material component. For example, a tool device according to the invention can also be used to join, for example, a metal part to a composite material component. List of reference symbols

[0169] 10Tool fixture 12Forming tool 14Contact area 16Workpiece 18Induction heating device 20Inductive heating mat 22High-frequency source device 24Heating area 26Susceptor 28Tool fixture 30Forming tool 32Layer of electrically conductive material 34Support area 36Punch 38First side 40Second side 110Induction heating device 112Support 114Coil fixture 115Inductive heating mat 116High-frequency strand 118Sheath 120High-frequency source device 122aConnection 122bConnection 124Connection 126Connection 128Spiral winding 130Row 132Column 134Turn 136Exit point 138aSpiral winding 138bSpiral winding 140aSpiral winding 140bSpiral winding 142aEdge winding section 142bEdge winding section 144aEdge winding section 144bEdge winding section 146First connection type 148Section 150Second connection type 152Edge winding section 154Third electrical connection type 156Edge winding section 158Straight section 170Tethering thread172Heating plate

Claims

1. Tool apparatus (10; 28) for producing a composite material component part, said tool apparatus comprising a forming tool (12; 30) having a contact region (14) for a workpiece (16), wherein the forming tool (12; 30) is made, in at least a portion thereof, of an electrically conductive material, and an induction heating apparatus (18; 110) having an inductive heating mat (20; 115), wherein the heating mat (20; 115) is positioned in spaced relation to the forming tool (12; 30), wherein a positioning of the workpiece (16) is provided between the heating mat (20; 115) and the forming tool (12; 30), in contact with the forming tool (12; 30), and wherein heating of the forming tool (12; 30) is provided, in at least a portion thereof, by the induction heating apparatus (18; 110), characterized by a punch (36) as a counter-element to the forming tool (12; 30), wherein the heating mat (20; 115) is integrated into the punch (36).

2. Tool apparatus in accordance with claim 1, characterized in that the electrically conductive material has an electrical conductivity which is at least 103 S / m, preferably at least 104 S / m, preferably at least 105 S / m and, in particular, at least 0.5 · 106 S / m.

3. Tool apparatus in accordance with claim 1 or 2, characterized in that the forming tool (12; 30) is made entirely of the electrically conductive material or has the electrically conductive material provided in a portion (32) thereof which is arranged and configured such that the workpiece (16) is heatable via heating said portion by the induction heating apparatus (18; 110), in particular wherein said portion is arranged or formed at the contact region (14) for the workpiece (16).

4. Tool apparatus in accordance with any one of the preceding claims, characterized in that the portion is formed from a layer (32) of electrically conductive material which is fixedly connected to a support region (34) of the forming tool (12; 30) or is placed on the support region (34), and in particular characterized in that the layer (32) of electrically conductive material is a coating on the forming tool (12; 30).

5. Tool apparatus in accordance with any one of the preceding claims, characterized in that the induction heating apparatus (18; 110) comprises an ohmic heating function, and in particular in that the workpiece (16) is also directly heatable via the induction heating apparatus (18; 110).

6. Tool apparatus in accordance with any one of the preceding claims, characterized in that at least one susceptor (26) is positioned between the workpiece (16) and the heating mat (20; 115), wherein the at least one susceptor (26) is permeable to electromagnetic fields of the heating mat (20; 115) such that the forming tool (12; 30) is heatable by the heating mat (20; 115), and the at least one susceptor (26) is heatable, in particular inductively heatable, by the heating mat (20; 115).

7. Tool apparatus in accordance with any one of the preceding claims, characterized in that the inductive heating mat (20; 115) is a mat that comprises a coil apparatus (114).

8. Tool apparatus in accordance with any one of the preceding claims, characterized in that the inductive heating mat (20; 115) is at least one of the following: - flexurally flexible; - flexurally elastic; - flexurally limp; - shape-retaining; - deformable and shape-retaining.

9. Tool apparatus in accordance with any one of the preceding claims, characterized in that the inductive heating mat (20; 115) comprises a carrier (112) and a coil apparatus (114) which is arranged on the carrier (112).

10. Tool apparatus in accordance with claim 7 or 9, characterized in that the coil apparatus (114) comprises a plurality of spiral-shaped windings (128) which are arranged in rows (130) and columns (132), and in particular characterized in that the spiral-shaped windings (128) are configured such that, when a current flows through the spiral-shaped windings (128), a direction of current is at least approximately in the same direction in adjacent peripheral winding sections (142a, 142b; 144a, 144b) of spiral-shaped windings (138a, 138b; 140a, 140b) adjacent in a row (130) or column (132), and in particular characterized by at least one of the following: - a first spiral-shaped winding (138a; 140a) comprises a first peripheral winding section (142a; 144a) and a second spiral-shaped winding (138b; 140b) comprises a second peripheral winding section (142b; 144b), wherein the first spiral-shaped winding (138a; 140a) and the second spiral-shaped winding (138a; 140b) are adjacent and wherein the first peripheral winding section (142a; 144a) and the second peripheral winding section (142b; 144b) are adjacent, and wherein when current flow occurs, the direction of current is at least approximately in the same direction in the first peripheral winding section (142a; 144a) and the second peripheral winding section (142b; 144b); - the direction of current is at least approximately in the same direction in both a row (130) and a column (132), when current flow occurs in adjacent peripheral winding sections (142a, 142b; 144a, 144b) of adjacent spiral-shaped windings (138a, 138b; 140a, 140b); - a sense of rotation of an electrical current is in the same sense within a spiral-shaped winding (128), and the senses of rotation are in opposite senses in adjacent spiral-shaped windings (128).

11. Tool apparatus in accordance with any one of claims 7, 9 or 10, characterized in that the coil apparatus (114) comprises at least one flat coil.

12. Tool apparatus in accordance with any one of claims 7, 9 to 11, characterized in that the coil apparatus (114) is formed by at least one high-frequency Litz wire (116), and in particular characterized in that the at least one high-frequency Litz wire (116) is held to a carrier (112) via one or more holding threads (170), and in particular in that the carrier (112) is a mesh network, and in particular in that the at least one high-frequency Litz wire (116) is sewn in place to the mesh network, and in particular in that the carrier (112) is a textile structure.

13. Method for producing a component part from a composite material by way of a forming tool (12; 30), in which method a workpiece (16) is placed in contact against the forming tool (12; 30) at a contact region (14) of the forming tool (12; 30), and at least a portion (24; 32) of the contact region (14) of the forming tool (12; 30) is non-contact heated by an inductive heating mat (20; 115), wherein the workpiece (16) is positioned between the contact region (14) and the heating mat (20; 115), and in which a punch (36) is used as a counter-element to the forming tool (12; 30), wherein the heating mat (20; 115) is integrated into the punch (36).

14. Method in accordance with claim 13, characterized by at least one of the following: - the heating mat (20; 115) itself is heated by ohmic heat and heats the workpiece (16) via ohmic heat; - a susceptor (26) is positioned between the heating mat (20; 115) and the workpiece (16), which susceptor (26) is permeable to electromagnetic fields of the heating mat (20; 115) such that the forming tool (12; 30) is inductively heated by the heating mat (20; 115), and wherein the susceptor (26) is inductively heated by the heating mat (20; 115); - the heating mat (20; 115) is adapted or is adaptable to a shape of a workpiece.