Method for vaporless processing of expandable or expanded particle foam material

Abstract

The invention relates to a method for vaporless processing of expandable or expanded particle foam material (2) for the production of a particle foam material part (4) in a mold cavity (4.3) of a mold (4).

Description

[0001] Process for the steam-free processing of expandable or expanded particle foam material

[0002] The invention relates to a method for the steam-free processing of expandable or expanded particle foam material for producing a particle foam molded part in a mold cavity of a mold, comprising the steps of: filling a mold cavity of a mold for the steam-free processing of expandable or expanded particle foam material with an expandable or expanded particle foam material and carrying out at least one measure for the steam-free introduction of thermal energy into the expandable or expanded particle foam material filled in the mold cavity for forming a particle foam molded part by means of a temperature control device assigned to the mold.

[0003] Corresponding methods for the steam-free and thus dry processing of expandable or expanded particle foam material for producing a particle foam molded part in a mold cavity of a mold are basically known from the prior art.

[0004] Corresponding processes are distinguished from conventional hot steam-based processes for processing expandable or expanded particle foam material to produce a particle foam molded part, in particular by the fact that the thermal energy required to bond the expandable or expanded particle foam material filled into the mold cavity is typically introduced into the expandable or expanded particle foam material predominantly conductively, i.e. predominantly based on heat conduction and thus without the use of hot steam flowing through the mold cavity.

[0005] Although steam-free processes can be used to produce particle foam moldings with excellent properties in a reproducible and therefore reliable manner, efforts are being made to further improve these processes. The aim is to further improve these processes, particularly with regard to aspects such as the efficiency and controllability of the manufacturing process, as well as the quality of the resulting particle foam moldings.

[0006] The invention is therefore based on the object of providing an improved method for the steam-free processing of expandable or expanded particle foam material for producing a particle foam molded part in a mold cavity of a mold.

[0007] The object is achieved by a method for the steam-free processing of expandable or expanded particle foam material according to independent claim 1. The dependent claims relate to possible embodiments of the method according to independent claim 1.

[0008] A first aspect of the invention relates to a method for the steam-free and thus dry processing of expandable or expanded particle foam material (hereinafter referred to as "particle foam material") for producing a particle foam molded part in a mold cavity of a mold. The method therefore relates to the steam-free and thus dry processing of particle foam material in a mold cavity of a mold to produce a particle foam molded part. The terms "steam-free" and "dry" mean that the thermal energy required to bond the particle foam material to form the particle foam molded part is introduced into the particle foam material conductively, in particular exclusively conductively, or in a conductive-convective manner, in particular exclusively conductively-convectively mixed, and thus in any case without the use of hot steam flowing through the mold cavity.

[0009] The method is therefore carried out using a mold designed for steam-free and thus dry processing of particle foam material. The mold comprises at least one mold element that delimits a mold cavity of the mold. The at least one mold element, which may also be referred to as a mold wall or a mold wall section, is typically mounted so as to be movable between an open position, in which access to the mold cavity is possible, e.g., for the purpose of removing a manufactured particle foam molded part, and a closed position, in which access to the mold cavity is not possible—apart from any smaller openings required, e.g., for venting.The mold can comprise a plurality of mold elements, which can optionally also be referred to as mold halves, which jointly define the mold cavity. If the mold comprises a plurality of mold elements, at least one mold element can be movably mounted relative to at least one other mold element in order to realize a corresponding open and closed position.

[0010] As mentioned, the molding tool is designed for steam-free and thus dry processing of particle foam material. Accordingly, a temperature control device is assigned to the molding tool, which is designed to introduce the thermal energy required to bond the particle foam material to form the particle foam molded part into the particle foam material conductively, in particular exclusively conductively, or in a conductive-convective mixed manner, in particular exclusively conductive-convective mixed manner, and thus in any case without the use of superheated steam flowing through the molding tool cavity. Accordingly, the molding tool does not have a steam chamber in which superheated steam can be stored to flow through the molding tool cavity.The wall sections of the mold that delimit the mold cavity or the wall sections of the mold element(s) that delimit the mold cavity therefore have no passage openings for the passage of hot steam into the mold cavity.

[0011] As will become apparent below, a corresponding temperature control device can be formed, for example, by or comprise a flow channel structure through which a temperature control medium, e.g., a gas and / or a liquid, can flow. A corresponding flow channel structure can comprise one or more flow channels extending in one or more spatial planes and / or directions outside or inside the mold, e.g., in particular outside or inside at least one mold element.During operation of a suitably configured temperature control device, a temperature control medium, optionally pressurized, can flow through the flow channel structure, thereby controlling the temperature of the wall sections of the mold that define the mold cavity. Thermal energy can be transferred via the wall sections of the mold that define the mold cavity into the mold cavity and thus to the particle foam material located in the mold cavity. Depending on the temperature level of the temperature control medium, the mold cavity or the particle foam material can be heated or, this applies particularly to a previously heated mold cavity, cooled.Thus, the at least one measure for the steam-free introduction of thermal energy into the particle foam material filled in the mold cavity to form a particle foam molded part, which is explained in more detail below and is carried out within the framework of the method, can be carried out by flowing a heated temperature control medium through a flow channel structure. As mentioned, the thermal energy required to bond the particle foam material to form the particle foam molded part is introduced into the particle foam material in a steam-free manner and thus conductively, in particular exclusively conductively, or conductively-convectively mixed, in particular exclusively conductively convectively mixed, and thus in any case without the use of hot steam flowing through the mold cavity.

[0012] The steps of the procedure are explained in detail below:

[0013] The method comprises a step of filling the mold cavity of the or a mold for the steam-free processing of particle foam material with an expandable or expanded particle foam material. The filling of the mold cavity with a particle foam material is carried out using a filling device assigned to the mold, which is configured to fill the mold cavity with particle foam material. A corresponding filling device can, for example, be configured to generate a conveying flow, which may be pressurized, i.e. in particular a gas flow, via which the particle foam material, possibly pressurized, is conveyed into the mold cavity. A corresponding filling device can therefore have one or more filling sections communicating with the mold cavity, via which filling sections particle foam material can be conveyed into the mold cavity.

[0014] The method further comprises a step of carrying out at least one measure for the steam-free introduction of thermal energy into the particle foam material filled in the mold cavity to form a particle foam molded part. Thus, by means of the at least one measure, sufficient thermal energy is introduced into the particle foam material filled in the mold cavity that the plastic particles are bonded to one another, in particular by so-called welding, to form the particle foam molded part to be produced. The at least one measure for the steam-free introduction of thermal energy into the particle foam material filled in the mold cavity to form a particle foam molded part is carried out by means of a temperature control device assigned to the mold.As mentioned above, according to the method, a tempering device is typically used which is designed to introduce the thermal energy required to bond the particle foam material filled into the mold cavity to form the particle foam molded part into the particle foam material conductively, in particular exclusively conductively, or conductively-convectively mixed, in particular exclusively conductively-convectively mixed, and thus in any case without the use of hot steam flowing through the mold cavity.

[0015] The method may further include a step of carrying out at least one measure for cooling the particle foam molded part in the mold cavity by means of the or a tempering device associated with the mold.

[0016] The method further comprises a step of carrying out at least one measure for, in particular pneumatically, controlling (the term “control” can also include “regulation”) the pressure in the mold cavity, during the filling of the mold cavity with the particle foam material and / or during the carrying out of at least one measure for the steam-free introduction of thermal energy into the particle foam material filled in the mold cavity for forming the particle foam molded part and / or during the carrying out of at least one measure for cooling the particle foam molded part in the mold cavity.

[0017] The at least one measure for controlling the pressure (this can alternatively or additionally also be understood as a regulation of the pressure) in the mold cavity during the filling of the mold cavity with the particle foam material and / or during the implementation of the at least one measure for the steam-free introduction of thermal energy into the particle foam material filled in the mold cavity for forming the particle foam molded part and / or during the implementation of the at least one measure for cooling the particle foam molded part in the mold cavity is carried out by means of a pressure control device assigned to the mold.The pressure control device is thus configured to carry out at least one measure for controlling the pressure in the mold cavity during the filling of the mold cavity with the particle foam material and / or during the carrying out of at least one measure for the steam-free introduction of thermal energy into the particle foam material filled in the mold cavity for forming the particle foam molded part and / or during the carrying out of at least one measure for cooling the particle foam molded part in the mold cavity.

[0018] The term “pressure” refers here to the gas pressure or the air pressure in the mold cavity or within the mold cavity.

[0019] The pressure control device is a separate device from the temperature control device. According to the method, it is therefore possible and specifically provided to control the pressure within the mold cavity independently of the temperature within the mold cavity (and vice versa), particularly during the filling of the mold cavity with the particle foam material and / or during the implementation of at least one measure for the vapor-free introduction of thermal energy into the particle foam material filled into the mold cavity to form the particle foam molded part and / or during the implementation of at least one measure for cooling the particle foam molded part in the mold cavity.According to the method, the at least one measure for controlling the pressure in the mold cavity is therefore carried out in particular independently of the implementation of the at least one measure for the steam-free introduction of thermal energy into the particle foam material filled in the mold cavity to form a particle foam molded part and / or independently of the implementation of the at least one measure for cooling the particle foam molded part in the mold cavity, although the implementation of the at least one measure for controlling the pressure in the mold cavity and the implementation of the at least one measure for the steam-free introduction of thermal energy into the particle foam material filled in the mold cavity to form a particle foam molded part and / or the implementation of the at least one measure for cooling the particle foam molded part in the mold cavity can take place in parallel at least at times.

[0020] A corresponding pressure control device can, as explained in more detail below, comprise, for example, a pressure accumulator filled with a pressurized pressure medium, in particular a pressurized gas, such as compressed air, and at least one pressure chamber configured in one or more parts, which communicates with the pressure accumulator and is assigned to the mold cavity and in particular surrounds the mold cavity at least partially, optionally completely. A corresponding pressure chamber can communicate with the mold cavity, for example via one or more openings (these can optionally also be realized by porous wall sections), so that a pressure level prevailing within the pressure chamber, i.e. in particular a gas or air pressure level prevailing within the pressure chamber, can be transferred to the mold cavity and thus to the particle foam material filled into the mold cavity.A corresponding pressure chamber can comprise one or more, in particular valve-like or valve-shaped, pressure control elements, which are configured to control the inflow of the or a pressurized pressure medium into the pressure chamber and / or the outflow of the or a pressurized pressure medium from the pressure chamber. As will also be explained in more detail below, the pressure control device is typically assigned a hardware and / or software-implemented control device, which is configured to control the operation of the pressure control device and thus the pressure level within the mold cavity.

[0021] The method is therefore characterized by the possibility, which can be realized or is realized by means of the pressure control device, of specifically generating and maintaining specific pressure levels, i.e. in particular gas or air pressure levels, within the mold cavity, regardless of the temperature within the mold cavity. As will be seen below, according to the method, specific pressure changes or profiles, i.e. in particular gas pressure changes or profiles, can be specifically generated and maintained within the mold cavity, regardless of the temperature within the mold cavity, in particular as a function of time. This surprisingly has an extremely positive effect on the processes taking place within the mold cavity as part of the method, i.e.the filling process, in which the mold cavity is filled with particle foam material, and / or the tempering process, in which the particle foam material filled into the mold cavity is tempered, i.e. in particular heated and / or cooled. In other words, by specifically setting appropriate pressure levels or profiles in the mold cavity, which may vary depending on the process and thus time, it is possible to specifically influence the processes taking place within the mold cavity as part of the method and thus the properties of the particle foam molded part to be produced. The possibility, which can be realized or is realized by means of the pressure control device, of specifically setting certain pressure levels or profiles within the mold cavity, regardless of the temperature within the mold cavity.-Progressions, completely new possibilities for process control are opened up, which have a positive effect on the efficiency and controllability of the process as well as on the quality of the particle foam molded parts produced using the process.

[0022] The method thus implements targeted pressure management within the mold cavity and takes advantage of the knowledge that the particle foam material, particularly due to its porous or cellular structure and / or the loading with compressed air and / or a blowing agent, is expandable and compressible, i.e., it has a certain expansion and compression capacity. This expansion or compression capacity enables not only purely mechanical deformation of the particle foam material, but also a deformation relevant to the principle described herein through a targeted increase or decrease in pressure—which, as mentioned, refers to the gas or air pressure—in the mold cavity.The deformation of the particle foam material resulting from a corresponding change in pressure in the mold cavity can be elastic and thus reversible or plastic and thus irreversible; the latter applies in particular when the particle foam material has a certain temperature, i.e. typically a temperature above a material-specific softening temperature.

[0023] This provides an improved method for the steam-free processing of expandable or expanded particle foam material for producing a particle foam molded part in a mold cavity of a mold.

[0024] In addition to the mentioned steps or processes of filling the mold cavity with particle foam material and carrying out at least one measure for the steam-free introduction of thermal energy into the particle foam material filled in the mold cavity to form a particle foam molded part by means of a temperature control device assigned to the mold, the method typically comprises further processes or steps.

[0025] This includes, for example, the already mentioned step of carrying out at least one measure for cooling the particle foam molded part in the mold cavity by means of the or a temperature control device assigned to the mold. Thus, within the scope of the method, after the formation of the particle foam molded part, by means of the at least one measure for the steam-free introduction of thermal energy into the particle foam material filled in the mold cavity to form a particle foam molded part by means of the or a temperature control device assigned to the mold, at least one measure for cooling the particle foam molded part in the mold cavity by means of the or a temperature control device assigned to the mold is typically carried out. The at least one measure for cooling the particle foam molded part in the mold cavity can therefore, for example,by flowing through the flow channel structure with a (comparatively) cool tempering medium.

[0026] The at least one measure for controlling the pressure in the mold cavity can also be carried out while the at least one measure for cooling the particle foam molded part is being carried out in the mold cavity by means of the pressure control device assigned to the mold. Here, too, the at least one measure for controlling the pressure in the mold cavity can be carried out independently of the at least one measure for cooling the particle foam molded part in the mold cavity. Consequently, the pressure level within the mold cavity can be controlled completely independently of the cooling processes while the at least one measure for cooling the particle foam molded part is being carried out in the mold cavity; in this way, the properties of the particle foam material to be produced or the resulting expansion can be specifically influenced.manufactured particle foam molding.

[0027] According to the method, the at least one measure for the steam-free introduction of thermal energy into the mold cavity can be carried out before and / or during filling of the mold cavity with a particle foam material. Thus, the mold cavity can be thermally preconditioned by the steam-free introduction of thermal energy before and / or during filling of the mold cavity, which can have a positive effect on the filling process and / or the subsequent tempering process and thus on the properties of the particle foam molded part to be produced or produced. The at least one measure for the steam-free introduction of thermal energy into the mold cavity before and / or during filling of the mold cavity can be carried out, for example, by means of the tempering device assigned to the mold.Alternatively or additionally, it is conceivable to temper a conveying flow generated by the filling device, by means of which the particle foam material is conveyed into the mold cavity.

[0028] As indicated, the at least one measure for controlling the pressure in the mold cavity can be carried out by a targeted introduction of a pressurized pressure medium, i.e., a pressurized gas, such as compressed air, into the mold cavity. Likewise, the at least one measure for controlling the pressure in the mold cavity, in particular after a corresponding introduction of a pressurized pressure medium into the mold cavity, can be carried out by a targeted discharge or release of a pressurized medium from the mold cavity.

[0029] The pressure medium introduced into the mold cavity via the pressure control device can also be temperature-controlled, so that thermal energy can also be introduced into the mold cavity via the pressure medium, additionally and independently of the actual measures for introducing thermal energy into the particle foam material, for example, for preconditioning the particle foam material. The at least one measure for controlling the pressure in the mold cavity can thus include at least temporarily introducing a pressurized pressure medium into the mold cavity that is heated to a heating or cooling temperature by means of an active or passive temperature control measure.The tempering measure can be carried out by at least one tempering device associated with the pressure control device; this is typically a tempering device separate from the tempering device associated with the molding tool.

[0030] As indicated, the pressure control device is typically assigned a hardware and / or software-implemented control device, which is configured to control the operation of the pressure control device and thus the pressure level within the mold cavity. The implementation of the at least one measure for controlling the pressure in the mold cavity can thus be carried out based on control information generated by a hardware and / or software-implemented control device, which enables precise, reproducible, and customizable control of the pressure level within the mold cavity.

[0031] The method can further comprise a step of detecting at least one chemical and / or physical parameter, i.e. in particular the pressure, the temperature, the composition of the chemical atmosphere, within the mold cavity and generating detection information describing the at least one detected chemical and / or physical parameter within the mold cavity. The step of detecting at least one chemical and / or physical parameter within the mold cavity and generating detection information describing the at least one detected chemical and / or physical parameter within the mold cavity can be carried out by means of a detection device assigned to the mold cavity. A corresponding detection device can be one or more detection elements arranged or formed on or in the mold, i.e. for exampleSensor elements, such as pressure sensor elements, temperature sensor elements, etc., whose detection signals can be described by the detection device in corresponding detection information, which, as will be explained below, can be used to control the method.

[0032] Corresponding detection information can thus be used, for example, by a corresponding control device to control the operation of the pressure control device and thus to control the pressure level within the mold cavity. A corresponding control device can thus generate the control information controlling the operation of the pressure control device based on or taking into account the detection information.

[0033] It was mentioned that the method, by means of the pressure control device, makes it possible to specifically generate and maintain certain pressure levels or pressure curves within the mold cavity, independently of all measures for tempering the mold cavity and thus the particle foam material located therein.

[0034] This can be implemented, for example, in such a way that a corresponding control device generates corresponding control information for controlling the operation of the pressure control device on the basis of pressure curve information stored in a data storage device implemented, for example, as a server, i.e. gas pressure curve information, which each defines a defined pressure curve, i.e. a gas pressure curve, within the mold cavity. A corresponding control device can therefore access predefined pressure curve information for controlling the operation of the pressure control device, which can reduce the effort required to control the operation of the pressure control device. Corresponding pressure curve information can be generated on the basis of information from databases, experiments, simulations, etc. Corresponding defined pressure curves can, in particular, be profile-like or-shaped, more particularly ramp-like or ramp-shaped, rising or falling pressure curves, and / or, in particular, plateau-like or plateau-shaped, pressure levels. In particular, respective defined pressure curves can thus describe time-dependently varying pressure levels.

[0035] Each pressure curve can define a, e.g., time-dependent, change in a pressure level in the mold cavity and / or a, e.g., time-dependent, maintenance of a pressure level in the mold cavity. A, e.g., time-dependent, change in a pressure level in the mold cavity can define an increase in a pressure level, i.e., in particular, an initial pressure level to a comparatively higher target pressure level, and / or a decrease in a pressure level, i.e., in particular, an initial pressure level to a comparatively lower target pressure level. Each pressure curve can therefore define a predefinable or predefined, in particular time-dependent, curve of a pressure level within the mold cavity, in particular a curve that can be described by a mathematical function.

[0036] Corresponding pressure profile information can be stored in the data storage device, e.g., in an ordered or categorized manner based on the material, mold, and / or molded part, so that, for example, predefined pressure profile information can be assigned to different particle foam materials to be processed and / or differently configured molds, e.g., with regard to the volume of the mold cavity, and / or differently configured particle foam molded parts, e.g., with regard to their geometric-structural design. In this way, material-, mold-, and / or molded part-specific differences can be taken into account when applying corresponding pressure profiles, and thus highly individualized or customized pressure levels or pressure profiles can be implemented with regard to a specific particle foam material in a specific mold for producing a specific particle foam molded part.A data storage device can be used in which pressure profile information is stored, which describes a defined, possibly time-dependently variable, pressure level in the mold cavity for a complete manufacturing process of a particle foam molded part, so that a (single) piece of pressure profile information defines the, possibly time-dependently variable, pressure level within the mold cavity for a complete process sequence for producing a particle foam molded part. Accordingly, at least one piece of pressure profile information can be stored in the data storage device.which defines a pressure profile during the filling of the mold cavity with the particle foam material, during the implementation of the at least one measure for the steam-free introduction of thermal energy into the particle foam material filled into the mold cavity to form a particle foam molded part, during the implementation of the at least one measure for cooling the particle foam molded part in the mold cavity and during demolding of the particle foam molded part from the mold cavity.

[0037] The expansion or compression capacity described above in connection with the particle foam material naturally also applies to the particle foam molded part formed from the particle foam material, so that its properties can also be specifically influenced by a targeted control of the pressure in the mold cavity.

[0038] In order to achieve a higher degree of granularity with regard to a process-dependent, optimized setting of a pressure level in the mold cavity, separate pressure curve information can be stored in the data storage device for individual, several, or all processes within the method. Thus, several separate pressure curve information items can be stored in the data storage device.wherein at least one item of pressure profile information defines a pressure profile during the filling of the mold cavity with the particle foam material, and / or at least one item of pressure profile information defines a pressure profile during the implementation of the at least one measure for the steam-free introduction of thermal energy into the particle foam material filled in the mold cavity to form a particle foam molded part, and / or at least one item of pressure profile information defines a pressure profile during the implementation of the at least one measure for cooling the particle foam molded part in the mold cavity, and / or at least one item of pressure profile information defines a pressure profile during demolding of a particle foam molded part from the mold cavity.

[0039] At least one item of pressure profile information can therefore be stored in the data storage device (and used by the pressure control device to control the pressure within the mold cavity), which defines a pressure profile during the filling of the mold cavity with the particle foam material, which results in compression of the particle foam material filled into the mold cavity. The pressure profile can define a first pressure level that is elevated compared to a reference pressure, such as atmospheric pressure (outside the mold cavity), and which is to be maintained during the filling of the mold cavity with the particle foam material. The compression of the particle foam material resulting from the elevated pressure can achieve higher filling levels of the mold cavity, which can, for example, have a positive effect on the properties of the particle foam molded part to be produced.However, as will be seen below, higher filling levels of the mold cavity can also have a positive effect on the process of bonding the plastic particles to form the particle foam molded part following the filling of the mold cavity, as the plastic particles are “forced” to come into closer contact with each other.

[0040] Alternatively or additionally, at least one pressure profile information item can be stored in the data storage device (and used by the pressure control device to control the pressure within the mold cavity), which defines a pressure profile during the implementation of the at least one measure for the steam-free introduction of thermal energy into the particle foam material filled in the mold cavity to form a particle foam molded part, which results in an expansion of the particle foam material filled in the mold cavity. The pressure profile can be a pressure profile that is different from a reference pressure, such as, for example,Atmospheric pressure, define a second pressure level that is elevated but reduced compared to the first pressure level (during filling of the mold cavity), which is to be maintained during the implementation of at least one measure for the vapor-free introduction of thermal energy into the particle foam material filled in the mold cavity to form a particle foam molded part. By expanding the particle foam material, the contact surfaces and thus the surfaces for the transfer of thermal energy between the individual plastic particles can be improved, as neighboring plastic particles press against one another due to expansion. This leads to an improved connection or welding of the plastic particles and thus to improved properties of the particle foam molded part to be produced or produced.As indicated, the expansion brought about by a corresponding second pressure level is expediently preceded by a compression of the plastic particles brought about by a corresponding first pressure level. When processing particle foam material loaded with a chemical and / or physical blowing agent, the second pressure level can also serve to prevent undesired escape of the blowing agent or to reduce this, in particular in a pressure-controlled manner, i.e., in particular, gas pressure-controlled. Alternatively or additionally, at least one item of pressure profile information can be stored orbe (and used by the pressure control device to control the pressure within the mold cavity), which defines a pressure profile during the implementation of the at least one measure for cooling the particle foam molded part in the mold cavity, which results in a targeted cooling of the particle foam molded part, in particular in the targeted formation of a defined microstructure of the particle foam molded part, further in particular in the formation of a targeted size and / or morphology of the plastic particles bonded together to form the particle foam molded part. The pressure profile can include at least one pressure level that is increased and / or reduced compared to the second pressure level, so that the plastic particles can be compressed again or (further) expanded during cooling, which gives rise to various possibilities for setting a defined micro- orCell structure of the particle foam molding.

[0041] Alternatively or additionally, at least one item of pressure profile information can be stored in the data storage device (and used by the pressure control device to control the pressure within the mold cavity), which defines a pressure profile during or during demolding of the particle foam molded part from the mold cavity, which results in demolding, i.e. in particular in a simplified and / or faster demolding of the particle foam molded part from the mold cavity, in particular the opened mold cavity. A corresponding pressure profile can, for example, cause a pressure increase, in particular a ramp-like or ramp-shaped one, within the mold cavity in order to release the particle foam molded part from the wall sections of the mold that delimit the mold cavity.

[0042] As mentioned, a pressure control device can be used according to the method, which can comprise, for example, a pressure accumulator filled with a pressurized pressure medium, in particular a pressurized gas, such as compressed air, and a pressure chamber communicating with the pressure accumulator, assigned to the mold cavity, in particular surrounding the mold cavity at least partially, if necessary completely. A corresponding pressure chamber can communicate with the mold cavity, for example via one or more openings, so that a pressure level prevailing within the pressure chamber can be transferred to the mold cavity and thus to the particle foam material filled in the mold cavity. A corresponding pressure chamber can have one or more, in particular valve-like or-shaped pressure control elements which are configured to control the inflow of the or a pressurized pressure medium into the pressure chamber and / or the outflow of the or a pressurized pressure medium from the pressure chamber. Respective pressure control elements can be transferred into at least one open position, in which an inflow of a pressurized pressure medium into the pressure chamber or an outflow of a pressurized pressure medium from the pressure chamber is possible, and into at least one closed position, in which an inflow of a pressurized pressure medium into the pressure chamber or an outflow of a pressurized pressure medium from the pressure chamber is not possible.In addition, at least one intermediate position between a respective open and a respective closed position can be realized, so that very specific, possibly time-dependent, varying pressure levels in the pressure chamber can be set.

[0043] It was mentioned that a corresponding temperature control device can be formed, for example, by or comprise a flow channel structure through which a temperature control medium, i.e., a gas and / or a liquid, can flow. A corresponding flow channel structure can comprise one or more flow channels which extend in one or more spatial planes and / or directions outside or inside the mold, i.e., in particular outside or inside at least one mold element. Corresponding flow channels can, as also mentioned, be formed by one or more channel-like or channel-shaped recesses which extend in one or more spatial planes and / or directions through at least one wall of the mold delimiting the mold cavity.Alternatively or additionally, corresponding flow channels can be formed by one or more separate, one- or multi-dimensional line elements, in particular formed in one or more spatial planes and / or directions, through which a temperature control medium can flow, i.e. pipe or hose elements, which are arranged on or in at least one wall section of the mold delimiting the mold cavity.

[0044] In connection with the particle foam material that can be processed according to the process, the following generally applies: the particle foam material that can be processed or processed according to the process typically has a particulate structure prior to processing. The particle foam material therefore typically consists of a large number of expandable or expanded plastic particles. Such plastic particles can be not yet expanded plastic particles, optionally loaded with a chemical and / or physical blowing agent; pre-expanded plastic particles, optionally loaded with a chemical and / or physical blowing agent residue; or largely expanded plastic particles, optionally loaded with a chemical and / or physical blowing agent residue.For both unexpanded and pre-expanded plastic particles, it is typically the case that they are (further) expandable and can therefore be (further) expanded in one expansion process. For (largely) expanded plastic particles, it is the case that they typically cannot be (significantly) expanded any further. Specific examples of particle foam materials or plastic particles that can be processed using this method include, but are not limited to, expandable or expanded polyolefins, such as expandable or expanded polyethylene, expandable or expanded polypropylene, and expandable or expanded polystyrene. In principle, all expandable or expanded thermoplastics, such as E-PA, E-PC, E-PBT, or E-PET, are suitable – whether petroleum / natural gas-based ('virgin'), containing recycled content, or even biogenic (from renewable raw materials).

[0045] A second aspect of the invention relates to a device for the steam-free processing of expandable or expanded particle foam material for producing a particle foam molded part. The device is particularly designed to carry out the method according to the first aspect of the invention, so that all statements relating to the method apply in principle analogously to the device.

[0046] The device comprises at least one mold defining a mold cavity for the steam-free processing of particle foam material, a filling device associated with the mold cavity, which is designed to fill the mold cavity with an expandable or expanded particle foam material; and at least one tempering device associated with the mold, which is designed to carry out at least one measure for the steam-free introduction of thermal energy into the particle foam material filled into the mold cavity for forming a particle foam molded part and / or for carrying out at least one measure for cooling the particle foam molded part in the mold cavity, and is characterized by a pressure control device associated with the mold, which is designed to carry out at least one measure for controlling the pressure, ie, as mentioned, in particular the gas pressure, in the mold cavity during the filling of the mold cavity with the expandable or expanded particle foam material and / or during the implementation of the at least one measure for the steam-free introduction of thermal energy into the particle foam material filled into the mold cavity for forming a particle foam molded part and / or during the implementation of the at least one measure for cooling the particle foam molded part in the mold cavity.

[0047] The pressure control device can comprise a pressure accumulator filled with a pressurized pressure medium, in particular a pressurized gas, such as compressed air, and a pressure chamber configured as one or more parts, communicating with the pressure accumulator and associated with the mold cavity, in particular surrounding the mold cavity at least partially, optionally completely. A pressure chamber configured as several parts can, for example, comprise several pressure chamber halves. The pressure chamber can communicate with the mold cavity, for example, via one or more openings, so that a pressure level prevailing within the pressure chamber can be transferred to the mold cavity.

[0048] The device may further comprise a hardware and / or software-implemented control device which is configured to generate control information for controlling the operation of the pressure control device.

[0049] The device may comprise a detection device configured to detect at least one chemical and / or physical parameter within the mold cavity and to generate detection information describing the at least one detected chemical and / or physical parameter within the mold cavity, wherein the or a control device is configured to generate control information for controlling the operation of the pressure control device on the basis of or taking into account the detection information.

[0050] The device may further comprise a data storage device in which pressure profile information is stored, each of which defines a pressure profile, in particular a profile-like or shaped pressure profile, within the mold cavity. The data storage device may be associated with the control device so that the control device can access and process the data stored in the data storage device.

[0051] At least one item of pressure profile information can be stored in the data storage device, which defines a pressure profile during the filling of the mold cavity with the expandable or expanded particle foam material, during the implementation of at least one measure for the vapor-free introduction of thermal energy into the particle foam material filled into the mold cavity to form a particle foam molded part, during the implementation of at least one measure for cooling the particle foam molded part in the mold cavity and during demolding of the particle foam molded part from the mold cavity.Alternatively or additionally, a plurality of separate pressure profile information items can be stored in the data storage device, wherein at least one piece of pressure profile information defines a pressure profile during the filling of the mold cavity with the expandable or expanded particle foam material, and / or at least one piece of pressure profile information defines a pressure profile during the implementation of at least one measure for the vapor-free introduction of thermal energy into the particle foam material filled into the mold cavity to form a particle foam molded part, and / or at least one piece of pressure profile information defines a pressure profile during the implementation of at least one measure for cooling the particle foam molded part in the mold cavity, and / or at least one piece of pressure profile information defines a pressure profile during demolding of the particle foam molded part from the mold cavity.

[0052] As mentioned, all statements in connection with the method according to the first aspect of the invention apply analogously to the device according to the second aspect of the invention.

[0053] The invention is explained again below with reference to the exemplary embodiments shown in the figures.

[0054] Fig. 1 - 5 each show a schematic diagram of an apparatus for the steam-free processing of particle foam material for carrying out a method according to an embodiment; and

[0055] Fig. 6 is a schematic diagram of a pressure curve in the mold cavity during the implementation of a method according to an embodiment.

[0056] Fig. 1 - 5 each show a schematic diagram of a device 1 for the steam-free and thus dry processing of particle foam material 2 (cf. e.g. Fig. 2) for producing a particle foam molded part 3 (cf. e.g. Fig. 4, 5), which is set up to carry out a method according to an embodiment.

[0057] The device 1 comprises a mold 4 designed for steam-free and thus dry processing of particle foam material 2. The mold 4 comprises in the embodiment two mold elements 4.1, 4.2, which

[0058] Limit the mold cavity 4.3 of the mold 4. The mold elements 4.1, 4.2, which may also be referred to as mold walls or mold wall sections, are movably mounted in an open position shown by way of example in Figs. 1, 5, in which access to the mold cavity 4.3 is possible, e.g. for the purpose of removing a produced particle foam molded part 3, and in a closed position shown by way of example in Figs. 2 - 4, in which - apart from any smaller openings required, e.g. for venting - no access to the mold cavity 4.3 is possible. Thus, at least one mold element 4.1, 4.2 is movably mounted relative to at least one other mold element 4.1, 4.2 by means of a drive device (not shown) in order to realize a corresponding open and closed position.

[0059] The molding tool 4 is designed for steam-free and thus dry processing of particle foam material 2. Accordingly, a temperature control device 5 is assigned to the molding tool 4, which is designed to introduce the thermal energy required to bond the particle foam material 2 to form the particle foam molded part 3 into the particle foam material 2 conductively, in particular exclusively conductively, or with a conductive-convective mix, in particular exclusively conductively and convectively, and thus in any case without the use of hot steam flowing through the molding tool cavity 4.3. Accordingly, the molding tool 4 does not have a steam chamber in which hot steam can be stored to flow through the molding tool cavity 4.3. The wall sections of the molding tool elements 4.1, 4.2 that delimit the molding tool cavity 4.3 therefore also do not have any through-openings for the passage of hot steam into the molding tool cavity 4.3.

[0060] In the exemplary embodiment, the tempering device 5 is formed by or comprises a flow channel structure 5.1, 5.2 through which a tempering medium, i.e., e.g., a gas and / or a liquid, can flow (indicated purely schematically in Fig. 1 as a line in the region of the wall sections of the mold elements 4.1, 4.2 that delimit the mold cavity 4.3). It is evident that each mold element 4.1, 4.2 can comprise a corresponding flow channel structure 5.1, 5.2, which can each be connected to a tempering medium supply (not shown) via supply lines 5.1.1, 5.2.1 and discharge lines 5.1.2, 5.2.2. A corresponding flow channel structure 5.1, 5.2 may comprise one or more flow channels (not shown) extending in one or more spatial planes and / or directions outside or inside the respective mold element 4.1, 4.2. A corresponding flow channel structure 5.1, 5.2 can be flowed through by a temperature control medium, optionally pressurized, which results in a temperature control of the wall sections of the mold elements 4.1, 4.2 that delimit the mold cavity 4.3, so that thermal energy can be transferred via the wall sections of the mold elements 4.1, 4.2 that delimit the mold cavity 4.3 into the mold cavity 4.3 and thus to the particle foam material 2 located in the mold cavity 4.3. Depending on the temperature level of the temperature control medium, the mold cavity 4.3 or the particle foam material can be heated in this way (cf. Fig. 3) or, this applies in particular to a previously heated mold cavity 4.3, cooled (cf. Fig. 4). Therefore, the at least one measure carried out within the scope of the method, which is explained in more detail below, for the steam-free introduction of thermal energy into the mold cavity 4.3 filled particle foam material 2 to form a particle foam molded part 3 by flowing through a flow channel structure 5.1, 5.2 with a heated tempering medium.

[0061] The flow channels of a corresponding flow channel structure 5.1, 5.2 can be formed by one or more channel-like or channel-shaped recesses formed in one or more spatial planes and / or directions by respective wall sections of the mold elements 4.1, 4.2 that delimit the mold cavity 4.3. Alternatively or additionally, the flow channels can be formed by one or more separate, one- or multi-dimensional line elements, e.g., pipe or hose elements, through which a temperature control medium can flow, shaped in particular in one or more spatial planes and / or directions, which are arranged on or in at least one wall section of a respective mold element 4.1, 4.2 that delimits the mold cavity 4.3.

[0062] The mold 4 is also assigned a filling device 6, which is configured to fill the mold cavity 4.3 with particle foam material 2. A corresponding filling device 6 can, for example, be configured to generate a conveying flow, i.e. in particular a gas flow, which may be pressurized, via which the particle foam material 2 is conveyed from a particle foam material reservoir (not shown), possibly pressurized, into the mold cavity 4.3 (cf. Fig. 2). As indicated in Figs. 1-5, a corresponding filling device 6 can thus have one or more filling sections (not labeled) communicating with the mold cavity 4.3, via which filling sections particle foam material 2 can be conveyed into the mold cavity 4.3.

[0063] As will become apparent below, the mold 4 is also assigned a pressure control device, which is configured to control the pressure or pressure level within the mold cavity 4.3 independently of the temperature control of the mold cavity 4.3 via the temperature control device 5. As mentioned, this refers to the gas pressure or gas pressure level within the mold cavity 4.3.

[0064] A corresponding pressure control device can, as indicated in Fig. 1 - 5, e.g. comprise a pressure accumulator 7.3 filled with a pressurized pressure medium, in particular a pressurized gas, such as compressed air, and a pressure chamber 7 (with its exemplary pressure chamber halves 7.1 and 7.2) communicating with the pressure accumulator, which is assigned to the mold cavity 4.3 and in particular surrounds the mold cavity 4.3 at least in sections, if necessary completely. In the exemplary embodiment, each mold element 4.1, 4.2 is assigned a corresponding pressure chamber half 7.1, 7.2, for example. A corresponding pressure chamber 7 or pressure chamber half 7.1, 7.2 can, e.g. B. via one or more openings (these can also be realized by porous wall sections), communicate with the mold cavity 4.3, so that a pressure level prevailing within the pressure chamber 7 or pressure chamber half 7.1, 7.2 is exerted on the mold cavity 4.3 and thus the particle foam material 2 filled into the mold cavity 4.3 can be transferred. The pressure chamber 7 or respective pressure chamber halves 7.1, 7.2 can comprise one or more, in particular valve-like or valve-shaped, pressure control elements 7.1.1, 7.2.1, which are configured to control an inflow of the or a pressurized pressure medium into the pressure chamber 7 or into respective pressure chamber halves 7.1, 7.2 and / or to control an outflow of the or a pressurized pressure medium from the pressure chamber 7 or from respective pressure chamber halves 7.1, 7.2. Respective pressure control elements 7.1.1, 7.2.1 can be in at least one open position, in which an inflow of a pressurized pressure medium into the pressure chamber 7 or into the respective pressure chamber halves 7.1, 7.2 or an outflow of a pressurized pressure medium from the pressure chamber 7 or from the respective pressure chamber halves 7.1, 7.2 is possible, and into at least one closed position in which an inflow of a pressurized pressure medium into the pressure chamber 7 or into the respective pressure chamber halves 7.1, 7.2 or an outflow of a pressurized pressure medium from the pressure chamber 7 or from the respective pressure chamber halves 7.1, 7.2 is not possible. In addition, at least one intermediate position can be realized between a respective open and a respective closed position, so that very targeted, possibly time-dependent varying pressure medium flows and pressure levels in the pressure chamber 7 or in the respective pressure chamber halves 7.1, 7.2 can be set.

[0065] As will also be explained in more detail below, the pressure control device is assigned a control device 8 implemented in hardware and / or software, which is designed to control the operation of the pressure control device and thus the pressure level within the pressure chamber 7 or within respective pressure chamber halves 7.1, 7.2 and thus within the mold cavity 4.3.

[0066] As mentioned, the device 1 for the steam-free processing of particle foam material 2 is designed to carry out a method according to an embodiment, the steps of which are explained in detail below:

[0067] The method comprises a step of filling the mold cavity 4.3 of the mold 4 with expandable or expanded particle foam material 2. The filling of the mold cavity 4.3 of the mold 4 with particle foam material 2 is carried out using the filling device 6. The step of filling the mold cavity 4.3 with particle foam material 2 is shown in the flow diagram shown as a schematic diagram in Fig. 6 in the process section labeled "II", which is clearly preceded by a process section labeled "I" for closing the mold 4.

[0068] The method further comprises a step of carrying out at least one measure for the steam-free introduction of thermal energy into the particle foam material 2 filled into the mold cavity 4.3 in process section II to form a particle foam molded part 3 (cf. Fig. 3). This process step is designated by "III" in the flow diagram shown in Fig. 6. Via the at least one measure, sufficient thermal energy is thus introduced into the particle foam material 2 filled into the mold cavity 4.3, either conductively or by a conductive-convective mixture, that the plastic particles are bonded to one another, in particular by so-called welding, to form the particle foam molded part 3 to be produced. The at least one measure for the steam-free introduction of thermal energy into the particle foam material 2 filled into the mold cavity 4.3 filled particle foam material 2 to form a particle foam molded part 3 is carried out by means of the temperature control device 5. From Fig. 6 it can be seen that the temperature indicated by line L1 within the mold cavity 4.3 in process step III is increased by corresponding operation of the temperature control device 5 and then maintained at a certain temperature level.

[0069] The method further comprises a step of carrying out at least one measure for cooling the particle foam molded part 2 in the mold cavity 4.3 (cf. Fig. 4). This process step is designated by "IV" in the flow diagram shown in Fig. 6. The at least one measure for cooling the particle foam molded part 3 in the mold cavity 4.3 can also be carried out by means of the temperature control device 5 by flowing a (comparatively) cool temperature control medium through at least one flow channel structure 5.1, 5.2. Fig. 6 shows that the temperature indicated by line L1 within the mold cavity 4.3 is reduced in process step IV by corresponding operation of the temperature control device 5.

[0070] For the sake of completeness, it should be noted that the method finally includes a step of demolding the particle foam molded part 3 from the mold 4 (see Fig. 5). This process step is designated "V" in the flow chart shown in Fig. 6.

[0071] What is essential for the method is that it includes a step of carrying out at least one measure for controlling (the term “control” can also include “regulation”) the pressure (cf. the exemplary lines L2 in Fig. 6) in the mold cavity 4.3 during the filling of the mold cavity 4.3 with the particle foam material 2 (cf. process step II) and / or during the carrying out of at least one measure for the steam-free introduction of thermal energy into the particle foam material 2 filled in the mold cavity 4.3 to form the particle foam molded part 3 (cf. process step III) and / or during the carrying out of at least one measure for cooling the particle foam molded part 3 in the mold cavity 4.3 (cf. process step IV) and / or during the demolding of the particle foam molded part 3 from the mold cavity 4.3 (cf. process step V). The at least one measure for controlling the pressure in the mold cavity 4.3 during the respective process steps II - V is carried out by means of the pressure control device and thus independently of the operation of the temperature control device 5. Accordingly, according to the method, in particular during one or more of the process steps II - V, it is possible and also specifically provided to control the pressure within the mold cavity 4.3 independently of the temperature within the mold cavity 4.3 (and vice versa). According to the method, the implementation of the at least one measure for controlling the pressure in the mold cavity 4.3 is thus carried out in particular independently of the implementation of the at least one measure for the steam-free introduction of thermal energy into the particle foam material 2 filled into the mold cavity 4.3 to form a particle foam molded part 3 according to process step III, although the implementation of the at least one measure for controlling the pressure in the mold cavity 4.3 and carrying out the at least one measure for the steam-free introduction of thermal energy into the particle foam material 2 filled into the mold cavity 4.3 to form a particle foam molded part 3, as shown in Fig.

[0072] 6, as illustrated by way of example, can take place in parallel, at least temporarily.

[0073] The method is therefore characterized by the possibility, realized or realizable by means of the pressure control device, of specifically generating and maintaining specific pressure levels within the mold cavity 4.3, regardless of the temperature within the mold cavity 4.3. As can be seen from the lines L2 in Fig. 6 indicating various exemplary pressure profiles within the mold cavity 4.3, the method allows specific pressure changes or profiles to be specifically generated and maintained within the mold cavity 4.3, regardless of the temperature within the mold cavity 4.3, in particular in a time-dependent manner. This surprisingly has a distinctly positive effect on the processes taking place within the mold cavity 4.3 as part of the method (cf. process steps II-V).In other words, by specifically setting appropriate pressure levels or profiles, which may vary depending on the process and thus time, it is possible to specifically influence the processes taking place within the mold cavity 4.3 as part of the method and thus the properties of the particle foam molded part 3 to be produced. The possibility, which can be realized or is realized by means of the pressure control device, of specifically generating and maintaining certain pressure levels or profiles within the mold cavity 4.3 regardless of the temperature within the mold cavity 4.3, thus opens up completely new possibilities for process control, which have a positive effect on the efficiency and controllability of the method as well as on the quality of the particle foam molded parts 3 that can be produced according to the method.

[0074] According to the method, the at least one measure for the steam-free introduction of thermal energy into the mold cavity 4.3 can already take place before and / or during the filling of the mold cavity 4.3. Thus, the mold cavity 4.3 can be thermally preconditioned before and / or during the filling process by steam-free introduction of thermal energy, which can have a positive effect on the filling process and / or the subsequent tempering process and thus on the properties of the particle foam molded part 3 to be produced or produced. The at least one measure for the steam-free introduction of thermal energy into the mold cavity 4.3 before and / or during the filling of the mold cavity 4.3 can be carried out, for example, by means of the tempering device 5. Alternatively or additionally, a tempering of a conveying flow by means of which the particle foam material 2 is conveyed into the mold cavity 4.3 is conceivable.

[0075] It should also be mentioned that the pressure medium provided via the pressure control device can also be temperature-controlled, so that thermal energy can also be introduced into the mold cavity 4.3 via the pressure medium, additionally, yet independently of the actual measures for introducing thermal energy into the particle foam material 2, for example for preconditioning the particle foam material 2. The at least one measure for controlling the pressure in the mold cavity 4.3 can thus include at least temporarily introducing a pressurized pressure medium, which is heated to a heating or cooling temperature by means of an active or passive temperature control measure, into the mold cavity 4.3.The tempering measure can be carried out by at least one tempering device (not shown) assigned to the pressure control device; this is typically a tempering device separate from the tempering device 5 assigned to the mold 4.

[0076] As indicated, the control device 8 is configured to control the operation of the pressure control device and thus the pressure level within the mold cavity 4.3. The implementation of the at least one measure for controlling the pressure in the mold cavity 4.3 is thus carried out based on control information generated by the control device 8, which enables precise, reproducible, and customizable control of the pressure level within the mold cavity 4.3.

[0077] The method can optionally further include a step of detecting at least one chemical and / or physical parameter, i.e. in particular the pressure, the temperature, the composition of the chemical atmosphere, within the mold cavity 4.3 and generating detection information describing the at least one detected chemical and / or physical parameter within the mold cavity 4.3. The step of detecting at least one chemical and / or physical parameter within the mold cavity and generating detection information describing the at least one detected chemical and / or physical parameter within the mold cavity can be carried out by means of a detection device 9 assigned to the mold cavity 4.3.A corresponding detection device 9 can comprise one or more detection elements (not shown) arranged or formed on or in the mold 4, i.e., sensor elements such as pressure sensor elements, temperature sensor elements, etc., whose detection signals can be described by the detection device 9 in corresponding detection information, which can be used to control the method.

[0078] Corresponding detection information can thus be used, for example, by the control device 8 to control the operation of the pressure control device and thus the pressure level within the mold cavity 4.3. The control device 8 can thus generate the control information controlling the operation of the pressure control device based on or taking into account the detection information. It was mentioned that the method, by means of the pressure control device and the pressure management in the mold cavity 4.3 that can be implemented with it, makes it possible to specifically generate and maintain specific pressure levels or pressure profiles within the mold cavity 4.3, independent of all measures for temperature control of the mold cavity 4.3 and thus of the particle foam material 2 located therein.

[0079] This can be implemented, for example, in such a way that the control device 8 generates corresponding control information for controlling the operation of the pressure control device on the basis of pressure curve information stored in a data storage device 10, implemented, for example, as a server, which pressure curve information each defines a defined pressure curve, i.e., in particular a defined gas or air pressure curve, within the mold cavity 4.3. Thus, the control device 8 can access predefined pressure curve information for controlling the operation of the pressure control device, which can reduce the effort required to control the operation of the pressure control device. Corresponding pressure curve information can be generated on the basis of information from databases, experiments, simulations, etc. Corresponding defined pressure curves can - as shown in Fig.6, as can be seen by way of example from the lines L2, in particular profile-like or profile-shaped, furthermore in particular ramp-like or ramp-shaped rising or falling pressure profiles, and / or, in particular plateau-like or plateau-shaped, pressure levels. In particular, respective defined pressure profiles can thus describe pressure levels that vary over time.

[0080] Each pressure curve can therefore define a, e.g., time-dependent, change in a pressure level in the mold cavity 4.3 and / or a, e.g., time-dependent, maintenance of a pressure level in the mold cavity 4.3. A, e.g., time-dependent, change in a pressure level in the mold cavity 4.3 can define an increase in a pressure level, i.e., in particular, an initial pressure level to a comparatively higher target pressure level, and / or a decrease in a pressure level, i.e., in particular, an initial pressure level to a comparatively lower target pressure level. Each pressure curve can therefore define a predefinable or predefined, in particular time-dependent, curve of a pressure level within the mold cavity 4.3, curve that can be described in particular by a mathematical function. As mentioned, various pressure curves are shown by way of example in Fig. 6 by the lines L2.

[0081] Corresponding pressure curve information can be stored in the data storage device 10, for example, in an ordered or categorized manner based on the material, mold, and / or molded part, so that, for example, predefined pressure curve information can be assigned to different particle foam materials 2 to be processed and / or, for example, with regard to the volume of the mold cavity 4.3, differently configured molds 4 and / or, for example, with regard to their geometric-structural design, differently configured particle foam molded parts 3. In this way, material-, mold-, and / or mold-part-specific differences can be taken into account when applying corresponding pressure curves, and thus, with regard to a specific particle foam material 2 in a specific mold 4 for producing a specific particle foam molded part 3, highly individualized or tailored pressure levels orPressure gradients are implemented.

[0082] Pressure profile information describing a defined, possibly time-dependently variable, pressure level in the mold cavity 4.3 for a complete manufacturing process of a particle foam molded part 3 can be or will be stored in the data storage device 10, so that a (single) piece of pressure profile information defines the, possibly time-dependently variable, pressure level within the mold cavity 4.3 for a complete process sequence (this would include process steps I-V in the flowchart according to Fig. 6) for producing a particle foam molded part 3. Accordingly, at least one piece of pressure profile information can be or will be stored in the data storage device 10, which describes a pressure profile during the filling of the mold cavity 4.3 with the particle foam material 2, during the implementation of at least one measure for the steam-free introduction of thermal energy into the mold cavity 4.3 filled particle foam material 2 for forming a particle foam molded part 3, during the implementation of the at least one measure for cooling the particle foam molded part 3 in the mold cavity 4.3 and during demolding of the particle foam molded part 3 from the mold cavity 4.3.

[0083] In order to achieve a higher degree of granularity with regard to a process-dependent, optimized setting of a pressure level in the mold cavity 4.3, separate pressure profile information can be stored in the data storage device 10 for individual, several, or all processes or process steps (cf. process steps I-V in the flow chart according to Fig. 6) within the method. Thus, several separate pressure profile information items can be stored in the data storage device 10, wherein at least one pressure profile information item defines a pressure profile during the filling of the mold cavity 4.3 with the particle foam material 2, and / or at least one pressure profile information item defines a pressure profile during the implementation of the at least one measure for the steam-free introduction of thermal energy into the mold cavity 4.3 filled particle foam material 2 for forming a particle foam molded part 3, and / or at least one piece of pressure curve information defines a pressure curve during the implementation of the at least one measure for cooling the particle foam molded part 3 in the mold cavity 4.3, and / or at least one piece of pressure curve information defines a pressure curve during demolding of a particle foam molded part 3 from the mold cavity 4.3. Accordingly, at least one piece of pressure curve information can be stored in the data storage device 10 (and used by the pressure control device to control the pressure within the mold cavity 4.3), which defines a pressure curve during the filling of the mold cavity 4.3 with the particle foam material 2, which results in a compression of the particle foam material 2 filled into the mold cavity 4.3. The pressure curve can, as shown in Fig.6, a first pressure level can be defined which is increased compared to a reference pressure, such as atmospheric pressure, and which is to be maintained during the filling of the mold cavity 4.3 with the particle foam material 2. The compression of the particle foam material 2 resulting from the increased pressure can achieve higher filling levels of the mold cavity 4.3, which can, for example, have a positive effect on the properties of a particle foam molded part 3 to be produced. As will become apparent below, higher filling levels of the mold cavity 4.3 can also have a positive effect on the process of bonding the plastic particles to form a particle foam molded part 3 following the filling of the mold cavity 4.3, as the plastic particles are "forced" to come into closer contact with one another.

[0084] Alternatively or additionally, at least one item of pressure profile information can be stored in the data storage device 10 (and used by the pressure control device to control the pressure within the mold cavity 4.3), which defines a pressure profile during the implementation of the at least one measure for the vapor-free introduction of thermal energy into the particle foam material 2 filled in the mold cavity 4.3 to form a particle foam molded part 3, which results in an expansion of the particle foam material 2 filled in the mold cavity 4.3. The pressure profile can, as shown in Fig. 6 by the dashed line L2, be increased compared to a reference pressure, such as atmospheric pressure, but lower than the first pressure level (during filling of the mold cavity 4.3) define a reduced second pressure level, which is to be maintained during the implementation of at least one measure for the steam-free introduction of thermal energy into the particle foam material 2 filled in the mold cavity 4.3 to form a particle foam molded part 3. By expanding the particle foam material 2, the contact surfaces and thus the surfaces for the transfer of thermal energy between the individual plastic particles can be improved, as neighboring plastic particles press against one another due to expansion. This leads to an improved connection or welding of the plastic particles and thus to improved properties of the particle foam molded part 3 to be produced or produced. As indicated, the expansion brought about by a corresponding second pressure level can expediently be preceded by a compression of the plastic particles brought about by a corresponding first pressure level.When processing particle foam material 2 loaded with a chemical and / or physical blowing agent, the second pressure level can also serve to prevent undesired escape of the blowing agent or to reduce this, in particular in a pressure-controlled manner.

[0085] Alternatively or additionally, at least one item of pressure profile information can be stored in the data storage device 10 (and used by the pressure control device to control the pressure within the mold cavity 4.3), which defines a pressure profile during the implementation of the at least one measure for cooling the particle foam molded part 3 in the mold cavity 4.3, which results in a targeted cooling of the particle foam molded part 3, in particular in the targeted formation of a defined microstructure of the particle foam molded part 3, further in particular in the formation of a targeted size and / or morphology of the plastic particles bonded together to form the particle foam molded part 3.The pressure curve can include at least one pressure level that is increased and / or reduced compared to the second pressure level, so that the plastic particles can optionally be compressed again or (further) expanded during cooling, resulting in various possibilities for setting a defined microstructure of the particle foam molded part 2.

[0086] Alternatively or additionally, at least one item of pressure profile information can be stored in the data storage device 10 (and used by the pressure control device to control the pressure within the mold cavity), which defines a pressure profile during demolding of the particle foam molded part 3 from the mold cavity 4.3, which results in demolding or simplified demolding of the particle foam molded part 3 from the, optionally opened, mold cavity 4.3. A corresponding pressure profile can, as indicated in Fig. 6 in process step V, e.g., cause a, in particular ramp-like, pressure increase within the mold cavity 4.3 in order to release the particle foam molded part 3 from the wall sections of the mold elements 4.1, 4.2 that delimit the mold cavity 4.3. Specifically, Fig.6 shows, by way of example, a short, sudden pressure increase which makes it possible to detach the particle foam molded part 3 more easily and / or more quickly from the wall sections of the mold elements 4.1, 4.2 which delimit the mold cavity 4.3.

Claims

PATE N TA NSP RÜ CHE 1. Method for the steam-free processing of expandable or expanded particle foam material (2) for the production of a particle foam molded part (4) in a mold cavity (4.3) of a mold tool (4), comprising the steps: - Filling a mold cavity (4.3) of a mold tool (4) for the steam-free processing of expandable or expanded particle foam material (2) with an expandable or expanded particle foam material (2); - Implementing at least one measure for the vapor-free introduction of thermal energy into the particle foam material (2) filled into the mold cavity (4.3) to form a particle foam molded part (3) by means of a temperature control device (5) associated with the mold (4), - Performing at least one measure for cooling the particle foam molded part (3) in the mold cavity (4.3) by means of the or a temperature control device (5) associated with the mold (4), characterized by - Carrying out at least one measure for controlling the pressure, in particular the gas pressure, in the mold cavity (4.3) during the filling of the mold cavity (4.3) with the expandable or expanded particle foam material (2) and / or during the carrying out of the at least one measure for the vapor-free introduction of thermal energy into the particle foam material (2) filled into the mold cavity (4.3) to form a particle foam molded part (3) and / or during the carrying out of the at least one measure for cooling the particle foam molded part (3) in the mold cavity (4.3) by means of the or a temperature control device (5) associated with the mold (4), by means of a pressure control device associated with the mold (4), wherein the carrying out of the at least one measure for controlling the pressure in the mold cavity (4.3) regardless of carrying out at least one measure for the vapor-free introduction of thermal energy into the particle foam material (2) filled into the mold cavity (4.3) to form a particle foam molded part (3) and / or regardless of carrying out at least one measure for cooling the particle foam molded part (3) in the mold cavity (4.3).

2. Method according to claim 1, further comprising carrying out at least one measure for introducing thermal energy into the mold cavity (4.3) without steam before and / or during the filling of the mold cavity (4.3) with the particle foam material (2) by means of the temperature control device (5) associated with the mold (4).

3. Method according to one of the preceding claims, wherein the at least one measure for controlling the pressure in the mold cavity (4.3) includes introducing and / or ejecting or draining a pressurized pressure medium into or out of the mold cavity (4.3).

4. Method according to claim 3, wherein the at least one measure for controlling the pressure in the mold cavity (4.3) includes at least temporary introduction and / or discharge or release of a pressurized pressure medium, tempered to a heating or cooling temperature by means of an active or passive tempering measure, into or out of the mold cavity (4.3).

5. Method according to one of the preceding claims, wherein the execution of the at least one measure for controlling the pressure in the mold cavity (4.3) is carried out on the basis of control information generated by a control device (8).

6. Method according to one of the preceding claims, further comprising detecting, by means of a detection device (9) associated with the mold cavity (4), at least one chemical and / or physical parameter within the mold cavity (4.3) and generating detection information describing the at least one detected chemical and / or physical parameter within the mold cavity (4.3), wherein the control device (8) generates the control information on the basis of or taking into account the detection information.

7. Method according to claim 5 or 6, wherein the control device (8) generates the control information on the basis of pressure profile information stored in a data storage device (10), which each define a pressure profile, in particular a profile-like or -shaped, within the mold cavity (4.3).

8. The method of claim 7, wherein at least one pressure profile information is stored in the data storage device (10), which defines a pressure profile during filling the mold cavity (4.3) with particle foam material (2), during the execution of at least one measure for the vapor-free introduction of thermal energy into the particle foam material (2) filled into the mold cavity (4.3) to form a particle foam molded part (3), during the execution of at least one measure for cooling the particle foam molded part (3) in the mold cavity (4.3), and during demolding of the particle foam molded part (3) from the mold cavity (4.3); and / or several separate pressure profile information is stored in the data storage device (10), wherein at least one pressure profile information defines a pressure profile during filling the mold cavity (4.3) with a particle foam material (2). defined, and / or at least one pressure profile information defines a pressure profile during the execution of at least one measure for the vapor-free introduction of thermal energy into the particle foam material (2) filled into the mold cavity (4.3) to form a particle foam molded part (3), and / or at least one pressure profile information defines a pressure profile during the execution of at least one measure for cooling the particle foam molded part (3) in the mold cavity (4.3), and / or at least one pressure profile information defines a pressure profile during demolding of the particle foam molded part (3) from the mold cavity (4.3).

9. Method according to claim 8, wherein at least one pressure profile information is stored in the data storage device (10), which defines a pressure profile during the filling of the molding tool cavity (4.3) with the expandable or expanded particle foam material (2), which results in a compression of the particle foam material (2) filled into the molding tool cavity (4.3).

10. Method according to claim 8 or 9, wherein at least one pressure profile information is stored in the data storage device (10), which defines a pressure profile during the execution of at least one measure for the vapor-free introduction of thermal energy into the particle foam material (2) filled into the mold cavity (4.3) for the formation of a particle foam molded part (3), which results in an expansion of the particle foam material (2) filled into the mold cavity (4.3).

11. Method according to one of claims 8 to 10, wherein at least one pressure profile information is stored in the data storage device (10), which defines a pressure profile during the execution of the at least one measure for cooling the particle foam molded part (3) in the molding tool cavity (4.3), which results in a targeted cooling of the particle foam molded part (3), in particular in the formation of a targeted micro- or cell structure of the particle foam molded part (3), and further in particular in the formation of a targeted size and / or morphology of the plastic particles forming the particle foam molded part (3).

12. Method according to one of claims 8 to 11, wherein at least one pressure profile information is stored in the data storage device (10), which defines a pressure profile during the demolding of the particle foam molded part (3) from the molding tool cavity (4.3), which results in demolding or a simplified demolding of the particle foam molded part (3) from the molding tool cavity (4.3).

13. Method according to one of the preceding claims, wherein a pressure control device is used which includes a pressure accumulator (7.3) filled with a pressurized pressure medium and at least one of the mold cavity (4.3) associated, in particular including the pressure chamber (7) surrounding at least section by section, or if necessary completely.

14. Method according to one of the preceding claims, wherein a forming tool (4) is used with a temperature control device (5) which comprises at least one flow channel through which a temperature control medium flows.

15. Device (1) for the steam-free processing of expandable or expanded particle foam material (2) for the production of a particle foam molded part (3), in particular according to a method according to one of the preceding claims, comprising: - a molding tool (4) limiting a molding cavity (4.3) for steam-free processing of expandable or expanded particle foam material (2), - a filling device (6) associated with the molding tool (4) which is set up to fill the molding tool cavity (4.3) with an expandable or expanded particle foam material (2); - at least one temperature control device (5) associated with the mold (4), which is configured to carry out at least one measure for the vapor-free introduction of thermal energy into the particle foam material (2) filled into the mold cavity (4.3) to form a particle foam molded part (3) and / or to carry out at least one measure for cooling a particle foam molded part (3) in the mold cavity (4.3); characterized by - a pressure control device associated with the mold (4), which is configured to carry out at least one measure for controlling the pressure, in particular the gas pressure, in the mold cavity (4.3) during the filling of the mold cavity (4.3) with particle foam material (2) and / or during the carrying out of at least one measure for the vapor-free introduction of thermal energy into the particle foam material (2) filled into the mold cavity (4.3) to form a particle foam molded part (3) and / or during the carrying out of at least one measure for cooling the particle foam molded part (3) in the mold cavity (4.3), wherein the pressure control device is configured to carry out the at least one measure for controlling the pressure in the mold cavity (4.3) independently of the carrying out of the at least one measure for the vapor-free introduction of thermal energy into the particle foam material (2) filled into the mold cavity (4.3).3) filled particle foam material (2) to form a particle foam molded part (3) and / or independently of carrying out at least one measure to cool the particle foam molded part (3) in the molding tool cavity (4.3).

16. Device according to claim 15, wherein the pressure control device comprises a pressure accumulator (7.3) filled with a pressurized pressure medium, in particular a pressurized gas, such as compressed air, and at least one communicating with it, associated with the mold cavity (4.3), in particular the mold cavity (4.3). at least partially, or if necessary completely, surrounding pressure chamber (7).

17. Device according to claim 16, wherein the at least one pressure chamber (7) communicates with the mold cavity (4.3) via one or more openings, so that a pressure level prevailing within the at least one pressure chamber (7) can be transferred to the mold cavity (4.3).

18. Device according to one of claims 15 to 17, further comprising a control device (8) which is configured to generate control information for controlling the operation of the pressure control device.

19. Device according to one of claims 15 to 18, further comprising a detection device (9) which is configured to detect at least one chemical and / or physical parameter within the mold cavity (4.3) and to generate detection information describing the at least one detected chemical and / or physical parameter within the mold cavity (4.3), wherein the or a control device (8) is configured to generate control information for controlling the operation of the pressure control device on the basis of or taking into account the detection information.

20. Device according to one of claims 15 to 19, further comprising a data storage device (10) in which pressure profile information, which defines a pressure profile, in particular a profile-like or -shaped, within the mold cavity (4.3), is stored.

21. Device according to claim 20, wherein at least one pressure profile information is stored in the data storage device (10), which defines a pressure profile during filling the mold cavity (4.3) with particle foam material, during the execution of at least one measure for the vapor-free introduction of thermal energy into the particle foam material (2) filled into the mold cavity (4.3) to form a particle foam molded part (3), during the execution of at least one measure for cooling the particle foam molded part (3) in the mold cavity (4.3) and during demolding of the particle foam molded part (3) from the mold cavity (4.3); and / or several separate pressure profile information is stored in the data storage device (10), wherein at least one pressure profile information defines a pressure profile during filling the mold cavity (4.3).3) defined with particle foam material (2), and / or at least one pressure profile information defines a pressure profile during the execution of the at least measure for the vapor-free introduction of thermal energy into the particle foam material (2) filled into the mold cavity (4.3) to form a particle foam molded part (3), and / or at least one. Pressure profile information defines a pressure profile during the execution of at least one measure for cooling a particle foam molded part (3) in the molding tool cavity (4.3), and / or at least one pressure profile information defines a pressure profile during demolding of a particle foam molded part (3) from the molding tool cavity (4.3).

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