Mold for processing a particle foam material to produce a particle foam molding

Abstract

The invention relates to a mold (1) for processing a particle foam material to produce a particle foam molding, comprising: at least one mold element (2) having at least one wall (2.1) that delimits at least some, optionally all of a mold cavity (3) of the mold (1) .

Description

[0001] Molding tool for processing a particle foam material to produce a particle foam molded part

[0002] The invention relates to a molding tool for processing a particle foam material to produce a particle foam molded part, which comprises at least one molding tool element having at least one wall which delimits a molding tool cavity of the molding tool at least in sections, optionally completely.

[0003] Corresponding molding tools are known in principle from the technical field of processing expandable or expandable particle foam materials for producing particle foam molded parts and typically comprise one or more molding tool elements, each of which has one or more walls which delimit or define, at least in sections, optionally completely, a molding tool cavity, i.e. in general a volume representing the geometric-constructive design of a particle foam molded part to be produced.

[0004] Furthermore, it is known that corresponding molds comprise one or more functional devices, such as tempering devices, which are designed to temper the mold cavity, ie generally to heat and cool the mold cavity.

[0005] Although particle foam moldings can be produced with satisfactory quality using known molding tools, there is a need for improvement and further development, for example with regard to a practical and reliable possibility of integrating functions relating to the manufacturing process of the respective particle foam moldings.

[0006] Based on this, the object of the invention is to provide an improved molding tool for processing a particle foam material to produce a particle foam molded part.

[0007] The object is achieved by a molding tool having the features according to independent claim 1. The dependent claims relate to possible embodiments of the molding tool according to independent claim 1.

[0008] A first aspect of the invention relates to a molding tool for processing a particle foam material to produce a particle foam molded part, such as a technical component or a technical component group. The molding tool is therefore generally designed for processing expandable or expanded particle foam material (hereinafter referred to as "particle foam material") to produce a particle foam molded part. The molding tool is therefore not an injection molding tool into which a plasticized plastic melt can be injected. The particle foam material that can be processed by means of the molding tool to produce a particle foam molded part typically has a particulate structure prior to its processing. The particle foam material that can be processed by means of the molding tool therefore typically consists of a plurality of expandable or expanded plastic particles.The corresponding plastic particles can be non-expanded plastic particles, optionally loaded with a chemical and / or physical blowing agent (residue), pre-expanded plastic particles, optionally loaded with a chemical and / or physical blowing agent (residue), or fully expanded plastic particles, optionally loaded with a chemical and / or physical blowing agent (residue). For non-expanded plastic particles as well as for pre-expanded plastic particles, it is typically (further) expandable and can therefore be (further) expanded in an expansion process. For fully expanded plastic particles, it is typically no longer (further) expandable. Concrete examples of particle foam materials that can be processed according to the process are:Plastic particles 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.

[0009] The molding tool can be configured to produce large-format or high-volume particle foam molded parts. Such large-format or high-volume particle foam molded parts are, in particular, particle foam molded parts with a spatial extension in at least one spatial direction of several centimeters or several decimetres. A particle foam molded part that can be produced using the molding tool can therefore, for example, have a height and / or width and / or depth of several centimeters or several decimetres.

[0010] In addition, the mold can be configured to produce thick-walled particle foam molded parts. Such thick-walled particle foam molded parts are, in particular, particle foam molded parts with wall thicknesses of several centimeters or several decimetres. A particle foam molded part produced using the mold can therefore, for example, have a wall thickness of several centimeters or several decimetres.

[0011] The mold comprises at least one mold element which has at least one wall which delimits or defines a mold cavity of the mold, i.e. generally a volume representing the geometric-structural design of a respective particle foam molded part to be produced, at least in sections, if appropriate completely. The at least one wall can be formed by one or more wall sections or comprise wall sections which extend in one or more spatial planes or directions. The at least one wall can therefore have, for example, a U-shaped cross-sectional geometry and thus one or more first wall sections extending in a first spatial plane or direction and one or more second wall sections extending in a second spatial plane or direction which is different from the first spatial plane or direction, i.e., at right angles to the first spatial plane or direction.Corresponding first wall sections can define, for example, a bottom wall, and corresponding second wall sections can define, for example, side walls of the at least one mold element. The at least one mold element can thus have, for example, a trough-like or tub-shaped configuration.

[0012] In all cases, a support structure can be assigned to the at least one wall, which supports the at least one wall. The support structure is typically arranged or formed on the surface of the at least one wall facing away from the mold cavity. The support structure can be formed by one or more, e.g., linear or planar, support elements or can comprise support elements that extend in one or more spatial planes or directions. The support structure can thus, for example, have an open or closed grid-like or grid-shaped configuration.

[0013] The molding tool comprises a flow channel structure which comprises a plurality of flow channels through which at least one flow medium can flow, which are arranged or formed in the at least one wall.

[0014] As will become apparent below, the flow channels can be configured differently in functional and / or structural terms and thus serve different functions in connection with the processing of a particle foam material to produce a particle foam molded part or perform different functions in connection with the processing of a particle foam material to produce a particle foam molded part. As will also become apparent below, the flow channels can be or have different flow media flowing through them, i.e. in particular flow media that serve different functions in connection with the processing of a particle foam material to produce a particle foam molded part. The functions assigned to the respective flow media are determined in particular by their chemical and / or physical properties, such as their state of aggregation, pressure, temperature, etc.

[0015] Consequently, at least one first flow channel can be or has a first flow medium with first properties flow through it, wherein the at least one first flow channel or the first flow medium performs a first function in connection with the processing of a particle foam material for producing a particle foam molded part, and at least one second or further flow channel can be or has a second or further flow medium with second or further properties flow through it, wherein the at least one second or further flow channel or the second or further flow medium performs a second or further function in connection with the processing of a particle foam material for producing a particle foam molded part. Respective first and second or further flow channels can be or have their respective first and second or further flow channels flowing at least temporarily at the same time or at least temporarily one after the other.another flow medium can or must flow through.

[0016] As will become apparent below, respective first flow channels differ from respective second or further flow channels in particular in that respective first flow channels have at least one flow channel section opening into the mold cavity, via which a flow medium can flow from the at least one first flow channel into the mold cavity. Respective first flow channels thus represent a first type of flow channel, which is characterized in that it has corresponding flow channel sections opening into the mold cavity. Respective second or further flow channels thus represent a second type of flow channel, which is characterized in that it does not have corresponding flow channel sections opening into the mold cavity.As will become apparent below, the flow channel structure may comprise a plurality of, optionally differently functionalized, flow channels of the first type, and / or a plurality of, optionally differently functionalized, flow channels of the second type.

[0017] There is no fluidic contact between the flow channels of the first and second types, so that it is not possible for a flow medium flowing through a respective flow channel of the first type to mix with a flow medium flowing through a respective flow channel of the second type. Thus, the flow channels of the first and second types are fluidically separated from one another, in particular such that a flow medium flowing through a flow channel of the first type cannot come into contact with a flow medium flowing through a flow channel of the second type. Respective flow channels of the first and second types can thus form separate flow channel substructures that do not fluidically communicate with one another, cannot fluidically influence one another, and, as will become apparent below, can be operated separately from one another in different functions.The molding tool can therefore be equipped with different functions by a targeted number and / or arrangement of differently functionalized flow channels, ie in particular by a targeted number and / or arrangement of respective flow channels of the first and second type, so that overall an improved molding tool is provided.

[0018] The flow channel structure can form a temperature control device or a component thereof, designed to control the temperature of the mold cavity, i.e., generally, to heat and cool the mold cavity and thus the particle foam material located therein to be processed by means of the mold. A corresponding temperature control device can be operated in at least one heating mode and in at least one cooling mode. The temperature control device can be operated in a first heating mode, in which the temperature control device is designed to introduce a specific amount of thermal energy into the mold cavity or the particulate particle foam material located therein to enable bonding of the particle foam material.Alternatively or additionally, the temperature control device can be operated in a second heating mode, in which the temperature control device is configured to introduce a specific amount of thermal energy into the mold cavity or the particulate foam material located therein in order to preheat the foam material. Further alternatively or additionally, the temperature control device can be operated in a third heating mode, in which the temperature control device is configured to introduce a specific amount of thermal energy into the mold cavity or the foam material located therein, which is combined to form a foam molded part, in order to reheat the foam material.The amount of thermal energy introduced into the particulate particle foam material in the first heating mode is typically higher, possibly significantly higher, than the amount of thermal energy introduced into the particle foam material in the second and / or third heating mode.

[0019] The tempering device can further be operated in a cooling mode in which a desired amount of thermal energy is removed from the mold cavity or from the particle foam molded part produced by bonding the particle foam material, in particular to enable demolding of the particle foam material.

[0020] The above-described implementation of corresponding heating and cooling modes can be realized specifically, for example, in that the at least one first flow channel, i.e. generally one or more flow channels of the first type, can be flowed through by a heating medium, in particular a vaporous one, for heating the mold cavity. The at least one second flow channel, i.e. generally one or more flow channels of the second type, can be flowed through by a cooling medium, in particular a liquid one, for cooling the mold cavity or can be flowed through by a heating medium, in particular a vaporous or liquid one, for preheating or postheating the mold cavity.

[0021] Respective first and second flow channels of a flow channel structure operated as a temperature control device therefore differ in their function, as respective first flow channels serve to heat the particle foam material located in the mold cavity, in particular in order to connect this to form a particle foam molded part, and can be flowed through by a heating medium, such as steam or superheated steam, or can be flowed through during operation of the temperature control device, and respective second flow channels serve to cool the particle foam material located in the mold cavity and / or to preheat and / or reheat the particle foam material located in the mold cavity and can be flowed through by a cooling medium, such as water, or can be flowed through during operation of the temperature control device.In addition, the respective first and second flow channels differ structurally for functional reasons, as the respective first flow channels each have at least one flow channel section opening into the mold cavity, via which a flow medium, ie in particular a heating medium, can flow from a respective first flow channel into the mold cavity. The respective second flow channels, in contrast, do not have corresponding flow channel sections via which a flow medium, ie in particular a cooling, preheating, or postheating medium, can flow from a respective second flow channel into the mold cavity.

[0022] The mold cavity, and thus the particle foam material located therein, can be heated by flowing a heating medium through the first flow channels and by flowing the heating medium from the respective flow channels into the mold cavity via respective flow channel sections. The arrangement and number of respective first flow channels and flow channel sections allows for targeted, uniform or uneven heating of the particle foam material located in the mold cavity. Thus, the amount of heating medium introduced, and thus the amount of thermal energy to be introduced into the mold cavity, can be specifically determined by the arrangement and number of respective first flow channels and flow channel sections.

[0023] The at least one first flow channel can be connectable or connected to a medium supply device providing a heating medium, i.e., for example, a container containing a heating medium. In particular, the connection between the at least one first flow channel and the medium supply device can be realized with the interposition of at least one distributor section or region, so that a heating medium can flow from the medium supply device first into the at least one distributor section or region and then into the at least one first flow channel.

[0024] Cooling of the mold cavity and thus the particle foam material contained therein can be achieved by flowing a cooling medium through the second flow channels, thus, in contrast to heating, (purely) convective. The arrangement and number of the respective second flow channels can achieve targeted, uniform or uneven cooling of the particle foam material located in the mold cavity. Thus, the amount of cooling medium introduced and, consequently, the amount of thermal energy to be extracted from the mold cavity can be specifically determined by the arrangement and number of the respective second flow channels.

[0025] Analogously, the preheating and / or postheating of the particle foam material in the mold cavity can be achieved (purely) convective by flowing a preheating and / or postheating medium through the second flow channels. The arrangement and number of the respective second flow channels can be used to achieve targeted, uniform or uneven preheating and / or postheating of the particle foam material in the mold cavity. Thus, the amount of preheating and / or postheating medium introduced, and thus the amount of thermal energy introduced into the mold cavity, can be specifically determined by the arrangement and number of the respective second flow channels.

[0026] The at least one second flow channel can be connectable or connected to a medium supply device providing a cooling, preheating, or postheating medium, i.e., for example, a container containing a cooling, preheating, or postheating medium. In particular, the connection between the at least one second flow channel and the medium supply device can be realized with the interposition of at least one distributor section or region, so that a cooling, preheating, or postheating medium can flow from the medium supply device first into the at least one distributor section or region and then into the at least one second flow channel.

[0027] The above-described configuration of the temperature control device, with respective first and second flow channels arranged or formed in the at least one wall and thus integrated into the at least one wall, enables the molding tool, unlike conventional molding tools, to have no steam chamber, which in known molding tools is arranged behind the walls defining the mold cavity to hold a vaporous heating medium. This provides advantages not only due to a comparatively significantly more compact design of the molding tool, but also with regard to the efficient operation of the molding tool.

[0028] The flow channel structure can alternatively or additionally form a gas injection device designed to inject a gas, such as compressed air, into the mold cavity or can be a component of such a device. The injection of a gas into the mold cavity can represent a function of the flow channel structure, e.g. for demolding a particle foam molded part from the mold cavity. In this case, the at least one first flow channel can be flowed through by a gas to be injected into the mold cavity, e.g. for demolding a particle foam molded part from the mold cavity. Alternatively or additionally, the flow channel structure can comprise at least one third flow channel arranged or formed in the wall, which can be flowed through by a gas to be injected into the mold cavity, e.g.for demolding a particle foam molded part from the mold cavity, and has at least one flow channel section opening into the mold cavity. Due to its configuration with at least one corresponding flow channel section, the at least one third flow channel also represents a flow channel of the first type. The at least one first and / or third flow channel can be or are connected to a gas injection device or blower device that generates a blowing flow, i.e. e.g. a pump device. In particular, the connection between the at least one first and / or third flow channel and the blower device can be realized with the interposition of at least one distributor section or region, so that a blowing flow from the blower device first flows into the at least one distributor section or region.-area and then into the at least one first and / or third flow channel.

[0029] Furthermore, alternatively or additionally, the flow channel structure can form a gas extraction device or a component thereof, designed to extract a gas from the mold cavity. The extraction of gas from the mold cavity can represent a function of the flow channel structure, e.g., for distributing and / or compressing particle foam material in the mold cavity. Alternatively or additionally, the extraction of gas from the mold cavity for venting the mold cavity can represent a function of the flow channel structure. In this case, the at least one first flow channel or a corresponding third flow channel can be flowed through by a gas to be extracted from the mold cavity, e.g., for distributing and / or compressing particle foam material in the mold cavity and / or for venting the mold cavity.Alternatively or additionally, the flow channel structure can comprise at least one fourth flow channel arranged or formed in the wall, through which a gas to be extracted from the mold cavity can flow, e.g. for distributing particle foam material in the mold cavity and / or for venting the mold cavity, and which has at least one flow channel section opening into the mold cavity. Due to its configuration with at least one corresponding flow channel section, the at least one third and / or fourth flow channel also represents a flow channel of the first type. A third and / or fourth flow channel configured accordingly for extracting gas can have smaller dimensions, i.e. in particular a smaller cross-sectional area, than a first and / or second flow channel.The same applies to respective flow channel sections of respective third and / or fourth flow channels opening into the mold cavity, which can therefore also have smaller dimensions, ie in particular a smaller cross-sectional area, than the flow channel sections of the at least one first flow channel.

[0030] The at least one first and / or third and / or fourth flow channel can be connectable or connected to a gas extraction device or suction device that generates a suction flow, i.e., for example, a pump device. In particular, the connection between the at least one first and / or third and / or fourth flow channel and the suction device can be realized with the interposition of at least one distributor section or region, so that a suction flow from the suction device can first flow into the at least one distributor section or region and then into the at least one first and / or third and / or fourth flow channel. The at least one mold element can have at least one, for example, channel-like or-shaped, distributor section or region, via which a flow medium, such as a heating medium, can flow into the at least one mold element and further into the at least one first flow channel. If a plurality of corresponding distributor sections or regions are assigned to the at least one first flow channel or respective flow channels of the first type, a first distributor section or region can form an inlet for a flow medium and a second distributor section or region can form a return for the flow medium. Respective first and second distributor sections or regions can thus be arranged or formed at or in the region of different free ends of the respective flow channel(s). Accordingly, respective flow channels can each open with a first end into a first distributor section or region.communicate with it and with a second end flow into a second distribution section or area or communicate with it.

[0031] Alternatively or additionally, the at least one mold element can comprise at least one distributor section or region assigned to the at least one second flow channel, i.e. generally to respective flow channels of the second type, via which a flow medium, such as a cooling, preheating or post-heating medium, can flow into the at least one mold element and further into the at least one second flow channel. If a plurality of corresponding distributor sections or regions are assigned to the at least one second flow channel or respective flow channels of the second type, a first distributor section or region can form an inlet for a flow medium and a second distributor section or region can form a return for the flow medium. Respective first and second distributor sections orThe flow channels can thus be arranged or formed at or in the region of different free ends of the respective flow channel(s). Accordingly, the respective flow channels can each open into or communicate with a first distributor section or region at a first end and open into or communicate with a second distributor section or region at a second end.

[0032] The at least one first and / or second flow channel - the same applies, if present, to the at least one third and / or fourth flow channel - can run at least partially, optionally completely, in a straight line in at least one spatial plane through the at least one wall. This configuration of the flow channels can, due to the comparatively simple geometry, e.g., bring manufacturing and flow-related advantages. Flow-related advantages can have an advantageous effect on the efficiency of the introduction or removal of thermal energy into the mold cavity via the flow medium flowing through the respective flow channels, iethe heating medium flowing through the at least one first flow channel, the cooling, preheating or post-heating medium flowing through the at least one second flow channel, the gas to be blown into the mold cavity flowing through the at least one third flow channel and / or the gas flowing through the at least one fourth flow channel and sucked out of the mold cavity.

[0033] The at least one first flow channel and / or second flow channel - the same applies, if present, to the at least one third and / or fourth flow channel - can run at least partially, optionally completely, bent, curved, or kinked in at least one spatial plane through the at least one wall. Specifically, the at least one first flow channel and / or second flow channel - the same applies, if present, to the at least one third and / or fourth flow channel - can run, for example, in a first spatial plane and in a second spatial plane oriented at an angle, optionally at right angles, to the first spatial plane through the at least one wall. In this way, it can be enabled or ensured, for example, that the flow medium flowing through the respective flow channel also flows in spatially differently oriented wall sections of the at least one mold element and, for example,a corresponding energy input is possible. The at least one wall can thus have a first wall section extending in a first spatial plane and at least one further wall section extending in a further spatial plane oriented at an angle, optionally at right angles, to the first spatial plane, wherein the at least one first flow channel and / or second flow channel - the same applies, if present, to the at least one third and / or fourth flow channel - extends through the first wall section and through the at least one further wall section.

[0034] The at least one first flow channel and / or second flow channel - the same applies, if present, to the at least one third and / or fourth flow channel - can run through the at least one wall in several spatial planes, in particular with respect to a reference plane of the mold cavity, furthermore in particular with respect to a base plane delimiting the mold cavity on the bottom, parallel or obliquely inclined, spatial planes. Thus, the flow channel (central) axes of at least one first flow channel segment and at least one second flow channel segment of a respective flow channel can be arranged in two parallel or obliquely inclined spatial planes. Such a configuration of the respective flow channels can also enable or ensure that the flow medium flowing through them flows in spatially differently aligned wall sections of the at least one mold element and, for example,appropriate energy input is possible.

[0035] The at least one first flow channel and / or second flow channel - the same applies, if present, to the at least one third and / or fourth flow channel - can have, at least in sections, two flow channel segments, in particular parallel, adjacent to, or one above the other. Thus, a respective flow channel can have, at least in sections, a meandering or shaped course extending in at least one spatial plane. A corresponding meandering or shaped course can, for example, serve to establish a connection to a corresponding distributor section or region via at least one flow channel segment. Specifically, a corresponding meandering or shaped course can thus be provided in a wall section of the at least one wall that borders a corresponding distributor section or region.

[0036] It is also conceivable for the flow channel (central) axes of different flow channels or types of flow channels to be arranged or formed in two parallel or obliquely inclined spatial planes. Respective flow channels or types of flow channels can thus be arranged or formed in parallel or obliquely inclined spatial planes, particularly with respect to their respective flow channel (central) axes. In general, respective flow channels or types of flow channels can thus be arranged or formed in one or more mutually offset spatial planes.

[0037] The at least one first flow channel and / or second flow channel - the same applies, if present, to the at least one third and / or fourth flow channel - can have, at least in sections, a round, rounded or ellipsoidal or oval or angular or polygonal cross-sectional geometry. The cross-sectional geometry of individual, several or all flow channels can generally be selected with regard to the desired flow properties of the respective flow medium as it flows through the respective flow channel. In this respect, differently dimensioned cross-sectional geometries are also conceivable, particularly along the longitudinal extent of the respective flow channels, for example in order to specifically realize different flow velocities of the flow medium as it flows through the respective flow channel in the manner of a Venturi channel, which in turn can influence, for example, the energy input or energy output.

[0038] In an analogous manner, the at least one flow channel section of a first flow channel and / or third flow channel and / or fourth flow channel opening into the mold cavity can have, at least in sections, a round, rounded, or angular cross-sectional geometry. The cross-sectional geometry of the or at least one flow channel section of a respective flow channel can generally be selected with regard to the desired flow properties of the flow medium as it flows into the mold cavity. In this respect, differently dimensioned cross-sectional geometries are also conceivable, particularly along the longitudinal extent of the respective flow channel, for example in order to specifically realize different flow velocities of the respective flow medium as it flows into the mold cavity in the manner of a Venturi channel, which in turn can influence, for example, the energy input.It is also conceivable for the at least one first flow channel and / or second flow channel - the same applies, if present, to the at least one third and / or fourth flow channel - to run at least partially, optionally completely, in a spiral or helical manner through the at least one wall. A corresponding spiral or helical course of individual, several, or all flow channels may optionally transport more flow medium per unit volume and thus, for example, introduce more thermal energy into the mold cavity or remove it from this mold cavity, which may, for example, influence the efficiency of the heating or cooling mode of the flow channel structure serving as a temperature control device.

[0039] It is also conceivable for several or all of the flow channels to extend, at least in sections, optionally completely, in a helical or double-helix configuration through the at least one wall, wherein the flow channels form a double-helix configuration. The respective helical or double-helix configurations can thus be arranged or formed concentrically but axially offset relative to a reference axis, such that respective helical or double-helix configurations of one flow channel are arranged or formed within the free spaces between respective helical or double-helix configurations of another flow channel. In this way, a particularly compact configuration of the flow channel structure can be realized, which, when implemented, for example, as a temperature control device, can enable more uniform heating and cooling of the mold cavity in terms of area.

[0040] With regard to the arrangement of the at least one first flow channel and / or second flow channel and / or third flow channel (if present) and / or fourth flow channel (if present), it can generally be assumed that these are arranged parallel at least in sections. In particular, the flow channel (central) axes of several or all, possibly different, flow channels can be arranged parallel. The distance between respective immediately adjacent flow channels can, for example, be in a range between 1 and 25 mm; the distance between respective first and second flow channels can therefore, for example, B. 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, 10mm, 11mm, 12mm, 13mm, 14mm, 15mm, 16mm, 17mm, 18mm, 19mm, 20mm, 21mm, 22mm, 23mm, 24mm or 25mm be.It is conceivable that the distance between all flow channels is the same or that flow channels have different distances in certain regions; thus, for example, flow channels arranged or formed in a first region of the at least one mold element can have a first distance from one another, and flow channels arranged or formed in at least one further region of the at least one mold element can have a further distance from one another that is different from the first distance. In principle, all configurations of the flow channel structure with multiple flow channels can be arranged or formed next to one another in an alternating arrangement. In this way, a configuration of the flow channel structure can also be realized which, viewed in terms of area, can enable, for example, more uniform heating and cooling of the mold cavity.

[0041] In particular, for example, first and second flow channels can be arranged or formed next to one another in an alternating arrangement, and at least one third and / or fourth flow channel can be arranged or formed in at least one region between at least two immediately adjacent first and second flow channels. Consequently, at least one third and / or fourth flow channel can be arranged or formed between individual, several, or all adjacent first and second flow channels. A corresponding third and / or fourth flow channel can be arranged or formed with its flow channel (central) axis parallel to or offset from the flow channel (central) axis of the first and / or second flow channel.

[0042] Coming back to a corresponding temperature control device, it should be added that this, in particular in addition to respective first and / or second flow channels, which, as described, in particular enable flow-based heating and cooling of the particle foam material located in the mold cavity, further comprises at least one electrical heating element arranged or formed in the at least one wall. The at least one electrical heating element, which can be a heating wire, for example, can serve, for example, to locally introduce additional thermal energy into the mold cavity and thus into the particle foam material located therein. In this way, for example, certain surface properties of the particle foam molded part to be produced or produced can be realized. The at least one electrical heating element can, for example,be arranged or formed in a wall section of the at least one wall laterally delimiting the mold cavity in order to realize certain surface properties in corresponding areas of the particle foam molded part.

[0043] In all embodiments, the molding tool is typically assigned a control device implemented in hardware and / or software for controlling the operation of the tempering device and / or a corresponding gas injection device (if present) and / or gas extraction device (if present).

[0044] The control device can, for example, be configured to control the operation of a corresponding temperature control device for heating the particle foam material located in the mold cavity, dependent on or independently of the operation of the temperature control device for cooling, preheating, and / or reheating the particle foam material located in the mold cavity. The control device can thus be configured to generate first control information for controlling the operation of the temperature control device for heating the particle foam material located in the mold cavity and, dependent on or independently thereof, further control information for controlling the operation of the temperature control device for cooling, preheating, and / or reheating the particle foam material located in the mold cavity, and to use this information as the basis for controlling the operation of the temperature control device.Controlling the operation of the temperature control device for heating the particle foam material located in the mold cavity includes, in particular, controlling at least one parameter of a heating medium flowing through the at least one first flow channel, in particular a relevant parameter influencing the heating output, such as, for example, the pressure, the temperature, the flow rate. Similarly, controlling the operation of the temperature control device for cooling, preheating, or reheating the particle foam material located in the mold cavity includes, in particular, controlling at least one parameter of a cooling, preheating, or reheating medium flowing through the at least one second flow channel, in particular a relevant parameter influencing the cooling, preheating, or reheating output, such as, for example, the pressure, the temperature, the flow rate.

[0045] The at least one mold element can also comprise at least one sensor element which is configured to detect at least one parameter influencing the heating power of the or a heating medium flowing through the at least one first flow channel and / or at least one sensor element which is configured to detect at least one parameter influencing the cooling, preheating or postheating power of the or a cooling, preheating or postheating medium flowing through the at least one second flow channel. Corresponding parameters can in particular be the pressure, the temperature or the flow velocity of the heating, cooling, preheating or postheating medium. The same applies to other flow media, such as, for example, corresponding gases blown into the mold cavity or sucked out of it.

[0046] In embodiments in which the temperature control device additionally comprises at least one corresponding electrical heating element, the control device can be configured, in particular, to control the operation of the temperature control device for heating the particle foam material located in the mold cavity and / or the operation of the temperature control device for cooling, preheating, or postheating the particle foam material located in the mold cavity dependently or independently of the operation of the at least one electrical heating element. In this way, the different temperature control principles can be used in a targeted manner to realize the desired properties of a particle foam molded part to be produced.

[0047] For all embodiments, the at least one mold element can be a mold half, a mold insert, or a slider or core. The at least one mold element can thus be designed as a mold half, a mold insert, a slider, or a core. A corresponding mold insert can be accommodated in a receptacle, e.g., formed by a recess, of a receiving device, which can also form a component of the mold. The same applies to corresponding sliders or cores.

[0048] For all embodiments, it further applies that the at least one mold element can be manufactured using an additive manufacturing process, in particular a powder-bed-based additive manufacturing process, such as a selective laser melting process, binder jetting process, etc., thus using 3D printing. In this way, the flow channels can be formed in any desired configuration, i.e., in particular, dimensions, shapes, spatial extensions, or orientations, directly with the at least one mold element, resulting in significant degrees of freedom with regard to design, construction, and production compared to conventional manufacturing processes.

[0049] Finally, for all embodiments, the mold can have multiple mold cavities and thus be configured as a multi-cavity mold. The multiple mold cavities can be delimited by corresponding walls of one or more mold elements.

[0050] It was mentioned that the molding tool can generally be designed to produce technical components or component groups. In particular, technical components or component groups with a plate-like or plate-shaped basic shape come into consideration. Furthermore, components or component groups to be installed in a vehicle, in particular a motor vehicle, with a plate-like or plate-shaped basic shape come into consideration. A concrete example of a component or component group that can be produced using the molding tool is a base body of a panel component, i.e. in particular a sun visor component. Corresponding panel components or sun visor components can be produced particularly practically using the molding tool due to the properties of the particle foam material that can be processed with the molding tool.

[0051] A second aspect of the invention relates to a method for processing a particle foam material to produce a particle foam molded part. The method is carried out using at least one molding tool element according to the first aspect of the invention and comprises, in particular, one, several, or all of the following steps: filling the molding tool cavity with a particle foam material to be processed to produce a particle foam molded part, heating the particle foam material located in the molding tool cavity by means of the temperature control device assigned to the at least one molding tool element, cooling and / or preheating and / or postheating the particle foam material and / or the particle foam molded part by means of the flow channel structure assigned to the at least one molding tool element, demolding the particle foam molded part from the molding tool cavity. The method can further comprise a step of blowing in a gas, e.g.Compressed air into the mold cavity, e.g. for demolding a particle foam molded part from the mold cavity, and / or a step of extracting a gas from the mold cavity, e.g. for compacting or distributing particle foam material in the mold cavity and / or for venting the mold cavity.

[0052] All statements in connection with the molding tool according to the first aspect of the invention apply analogously to the method according to the second aspect of the invention and vice versa.

[0053] The invention is explained using exemplary embodiments in the drawings. In the drawings:

[0054] Fig. 1 - 3 each show schematic diagrams of a molding tool according to embodiments;

[0055] Fig. 4 - 7 each show representations of a mold according to a further embodiment; and

[0056] Fig. 8 - 11 each show schematic diagrams of a molding tool according to another embodiment.

[0057] Figs. 1-3 and Figs. 8-11 each show schematic diagrams of a section of a molding tool 1 for processing an expandable or expanded particle foam material to produce a particle foam molded part. A specific configuration of the or a corresponding molding tool 1 is shown in Figs. 4-7.

[0058] The figure shows that the mold 1 comprises a mold element 2, which has at least one wall 2.1 that delimits a mold cavity 3 of the mold 1 at least partially, optionally completely. In the schematic diagrams according to Figs. 1-3 and Figs. 8-11, a corresponding wall 2.1 of a mold element 2 is shown in a sectional view only because this is initially relevant for the purposes of explaining the principle described herein.

[0059] The or one wall 2.1 can, as can be seen from Figs. 4 - 7, be formed by one or more wall sections or comprise such sections which extend in one or more spatial planes or directions. The or one wall 2.1 can, as can also be seen from Figs. 4 - 7, thus have, for example, a U-shaped cross-sectional geometry and thus one or more first wall sections extending in a first spatial plane or direction and one or more second wall sections extending in a second spatial plane or direction that is different from the first spatial plane or direction, i.e., perpendicular to the first spatial plane or direction, wherein corresponding first wall sections can define a bottom wall and corresponding second wall sections can define side walls of the mold element 2. The mold element 2 can thus have a trough-like or -shaped configuration.

[0060] The molding tool 1 further comprises a flow channel structure 4, which is functionalized, for example, as a temperature control device, and which is generally designed to temperature control the molding tool cavity 3 or the particle foam material located in the molding tool cavity 3, i.e., generally to heat and cool the molding tool cavity 3 or the particle foam material located in the molding tool cavity 3. In particular, the temperature control device is designed to introduce a desired amount of thermal energy into the molding tool cavity 3 or the particulate particle foam material located therein in a heating mode during operation of the molding tool 1, in particular to enable the particle foam material to bond, and to remove a desired amount of thermal energy from the molding tool cavity 3 or the particulate particle foam material located therein in a cooling mode.from the particle foam molded part produced by joining the particle foam molded part, in particular to enable demolding of the particle foam material.

[0061] The tempering device can also be configured to preheat and / or reheat the particle foam material located in the mold cavity 3.

[0062] In the exemplary embodiments according to Figs. 1-7, the flow channel structure 4 is formed by a plurality of first flow channels 4.1 and a plurality of second flow channels 4.2 or comprises a plurality of first flow channels 4.1 and a plurality of second flow channels 4.2, which, as Figs. 1-3 show by way of example, are each arranged or formed in the wall 2.1 of the mold element 2.

[0063] The first flow channels 4.1 can each be flowed through by a heating medium, in particular a vaporous one, for heating the mold cavity 3, wherein the first flow channels 4.1 each have a plurality of flow channel sections 4.1.1 opening into the mold cavity 3, via which a heating medium can flow from the respective first flow channels into the mold cavity 3. It can be seen from Figs. 4-7 that respective flow channel sections 4.1.1 can be arranged or configured distributed, for example, along the longitudinal axis or extension of the respective first flow channels 4.1.

[0064] The second flow channels 4.2 can each be flowed through by a cooling medium, in particular a liquid one, for cooling the mold cavity 3.

[0065] It can be seen from the figure that the first and second flow channels 4.1, 4.2 differ initially in their function, as the first flow channels 4.1 serve to heat the mold cavity 3 and can be flowed through by a heating medium, such as steam or superheated steam, or are or are flowed through during operation of the temperature control device 4, and the second flow channels 4.2 serve to cool the mold cavity 3 and can be flowed through by a cooling medium, such as water, or are or are flowed through during operation of the temperature control device. Individual, several or all of the second flow channels 4.2 can also be used to preheat and / or reheat the particle foam material located in the mold cavity 3 and can be flowed through by a preheating and / or reheating medium, such as tempered water, or are or are flowed through during operation of the temperature control device.In addition, the first and second flow channels 4.1, 4.2 differ structurally in terms of their function, as the first flow channels 4.1 each have a plurality of flow channel sections 4.1.1 opening into the mold cavity 3, via which a heating medium can flow from the respective first flow channels 4.1 into the mold cavity 3. The second flow channels 4.2, on the other hand, do not have corresponding flow channel sections via which a flow medium flowing through them, i.e., for example, a cooling medium, can flow from the respective second flow channels 4.2 into the mold cavity 3.

[0066] The particle foam material located in the mold cavity 3 can thus be heated by a heating medium flowing through the first flow channels 4.1 and by the heating medium flowing from the respective flow channels 4.1 via respective flow channel sections 4.1.1 into the mold cavity 3. The arrangement and number of respective first flow channels 4.1 and flow channel sections 4.1.1 allows for targeted, uniform or uneven heating of the particle foam material located in the mold cavity 3. Thus, the amount of heating medium introduced and, consequently, the amount of thermal energy to be introduced into the mold cavity 3 can be specifically determined by the arrangement and number of respective first flow channels 4.1 and by the arrangement and number of respective flow channel sections 4.1.1.

[0067] The cooling of the particle foam material located in the mold cavity 3—the same applies to preheating and / or postheating—can be achieved by flowing a cooling medium through the second flow channels 4.2, thus, in contrast to heating, (purely) convective. Through the arrangement and number of respective second flow channels 4.2, a targeted, uniform or uneven cooling of the particle foam material located in the mold cavity 3 can be achieved. Thus, the amount of cooling medium introduced and, consequently, the amount of thermal energy to be discharged from the mold cavity can be specifically determined by the arrangement and number of respective second flow channels.

[0068] The figures show that there is no fluidic contact between the first and second flow channels 4.1, 4.2, so that it is not possible for a flow medium flowing through a respective first flow channel 4.1, such as a heating medium, to mix with a flow medium flowing through a respective second flow channel 4.2, such as a cooling medium. Consequently, the first flow channels 4.1 are fluidically separated from the second flow channels 4.2, in particular in such a way that a flow medium flowing through a respective first flow channel 4.1 cannot come into contact with a flow medium flowing through a respective second flow channel 4.2. The respective first and second flow channels 4.1, 4.2 can thus form separate flow channel substructures which do not communicate with each other in terms of flow technology, cannot influence each other in terms of flow technology and which, as will become apparent below, can be operated in particular separately from each other, e.g. for heating and cooling the particle foam material located in the mold cavity 3.

[0069] The configuration of the flow channel structure 4 shown in the figures, with respective first and second flow channels 4.1, 4.2 arranged or formed entirely in or within the wall 2.1 and thus completely integrated into the wall 2.1, enables the mold 1, unlike conventional molds, to have no steam chamber, which in known molds is arranged behind the walls defining the mold cavity in order to retain a vaporous heating medium. This provides not only advantages due to a comparatively significantly more compact design of the mold 1 but also advantages with regard to the efficient operation of the mold 1.

[0070] 1-3 show, by way of example and not exhaustively, different configuration options for the first and second flow channels 4.1, 4.2, which in Fig. 1 are arranged alternately in a common plane and in Fig. 2 are arranged alternately in the vertical direction (z-direction) and are thus arranged or formed at least in sections in two planes. In Figs. 1, 2, the first and second flow channels 4.1, 4.2 each have, by way of example, a round or rounded cross-sectional geometry. The flow channel sections 4.1.1 which open into the mold cavity 3 from the respective first flow channels 4.1 typically have an unchanged cross-sectional geometry and can therefore be designed as hollow cylinders, as Figs. 1-3 show by way of example.

[0071] Fig. 3 shows, purely schematically, an embodiment in which the first and second flow channels 4.1, 4.2 have a circular segment-shaped, i.e., in particular semicircular, cross-sectional geometry. The adjacent arrangement of the first and second flow channels 4.1, 4.2 is intended to indicate that both the respective first flow channels 4.1 and the respective second flow channels 4.2 can each run helically or wound in a helical manner through the wall 2.1, wherein the first and second flow channels 4.1, 4.2, in particular in pairs, can form a double-helix-like or double-helix-shaped arrangement. The respective helically wound first and second flow channels 4.1, 4.2 can thus be arranged or formed concentrically but axially offset with respect to a reference axis (e.g. the y-axis), so that the helically wound flow channel sections of a respective second flow channel 4.2 are arranged or formed within the free spaces between the helically wound flow channel sections of a respective first flow channel 4.1. In this way, a particularly compact configuration of the flow channel structure 4 can be realized, which, when the flow channel structure 4 serves as a temperature control device, can enable a more uniform heating and cooling of the particle foam material located in the mold cavity 3 in terms of area.

[0072] As mentioned, a concrete configuration of a mold element 2 designed as a mold insert of an embodiment of a mold 1 is shown in Figs. 4-7. Fig. 4 shows a partially transparent plan view of the mold element 2, Fig. 5 shows a sectional view through the mold element 2 along the section lines V-V, Fig. 6 shows a sectional view through the mold element 2 along the section lines VI-VI, and Fig. 7 shows a sectional view through the mold element 2 along the section lines VII-VII.

[0073] Based on the plan view shown in Fig. 4 of the mold element 2 shown as an example arranged on a clamping plate 5, the already mentioned alternating parallel arrangement possibility of respective first and second flow channels 4.1, 4.2 is initially apparent.

[0074] Furthermore, it can be seen from the top view shown in Fig. 4 that the molding tool element 2 can comprise a plurality of channel-like or shaped distributor sections or regions 8.1, 8.2 assigned to the first flow channels 4.1, via which a heating medium can flow into the molding tool element 2 and further into the first flow channels 4.1 or out of the first flow channels 4.1 and further out of the molding tool element 2. In the exemplary embodiment, a first distributor section or region 8.1 is assigned to the first flow channels 4.1, which forms an inlet for a heating medium via a connection 9.1, and a second distributor section or region 8.2 is assigned to the first flow channels 4.1, which forms a return for the heating medium via a connection 9.2. Respective first and second distributor sections or regions 8.1, 8.2 can be arranged or formed at or in the region of different free ends of the first flow channels 4.1.Accordingly, the first flow channels can open into the first distributor section or region 8.1 with a respective first end or communicate with it and open into the second distributor section or region 8.2 with respective second ends or communicate with it (see also the sectional view according to Fig. 5).

[0075] Corresponding connections 9.1, 9.2 can be connectable or connected to a heating medium supply device (not shown) providing a heating medium, i.e., for example, a container containing a heating medium. The connection between the first flow channels 4.1 and the heating medium supply device can thus be realized with the interposition of the distributor sections or regions 8.1, 8.2, so that a heating medium can flow from the heating medium supply device first into one distributor section or region 8.1 and then into the first flow channels 4.1. It can also be seen from Fig. 5 that the first flow channels 4.1 can each have, at least in sections, two flow channel segments (not labeled), in particular parallel, adjacent to, or one above the other. Consequently, a first flow channel 4.1 can, at least in sections, have a flow channel extending in at least one spatial plane (cf., for example, the image plane in Fig.5). In the exemplary embodiment, the meandering or shaped course serves to establish a connection to a corresponding distributor section or region 8.1, 8.2 via at least one flow channel segment. Specifically, the meandering or shaped course of the first flow channel 4.1 in the exemplary embodiment is provided in a vertical wall section which borders on a corresponding distributor section or region 8.1, 8.2, so that one flow channel segment merges with the corresponding distributor section or region 8.1, 8.2. In the view according to Fig. 5, the flow channel segments are accordingly oriented vertically by way of example and arranged parallel with respect to a vertical spatial axis.

[0076] The same applies to the second flow channels 4.2, which can therefore also have a corresponding meandering or shaped course, at least in sections, in a corresponding arrangement.

[0077] In addition, Fig. 4 shows that the mold element 2 can comprise a plurality of channel-like or -shaped distributor sections or regions 10.1, 10.2 assigned to the second flow channels 4.2, via which a cooling medium can flow into the mold element 2 and further into the second flow channels 4.2 or out of the second flow channels 4.2 and further out of the mold element 2. In the exemplary embodiment, a first distributor section or region 10.1 is assigned to the second flow channels 4.2, which forms an inlet for a cooling medium via a connection 11.1, and a second distributor section or region 10.2 is assigned to the second flow channels 4.2, which forms a return for the cooling medium via a connection 11.2. Respective first and second distributor sections or regions 10.1, 10.2 can be arranged or formed at or in the region of different free ends of the second flow channels 4.2. Accordingly, the second flow channels 4.2 with a respective first end open into the first distribution section or area 10.1 or communicate with it and with respective second ends open into the second distribution section or area 10.2 or communicate with it.

[0078] Corresponding connections 11.1, 11.2 can be connectable or connected to a cooling medium supply device (not shown) providing a cooling medium, i.e. e.g. a container containing a cooling medium. The connection between the second flow channels 4.2 and the cooling medium supply device can thus be realized with the interposition of the distributor sections or regions 10.1, 10.2, so that a cooling medium can flow from the cooling medium supply device first into one distributor section or region 10.1 and then into the second flow channels 4.2. Based on the sectional views according to Figs. 5 - 7, it is again apparent, analogous to Fig. 1, that the first and second flow channels 4.1, 4.2 can run straight in a spatial plane through the wall 2.1. This configuration of the first and second flow channels can, due to the comparatively simple geometry, e.g.This can bring manufacturing and fluidic advantages. Fluidic advantages can have a beneficial effect on the efficiency of the introduction or removal of thermal energy into or from the mold cavity 3 via the heating or cooling medium flowing through the first or second flow channels 4.1, 4.2.

[0079] From the sectional view according to Fig. 5, it can be seen that the first flow channels 4.1—the same applies to the second flow channels 4.2—can extend through the wall 2.1, at least in sections, in at least one spatial plane. Specifically, it is shown by way of example that the first flow channels 4.1 can extend through the wall 2.1 in a first spatial plane as well as in a second spatial plane oriented (essentially) at right angles to the first spatial plane. In this way, it is enabled or ensured in the exemplary embodiment that the heating medium flowing through the first flow channels 4.1 also flows in spatially differently oriented wall sections of the wall 2.1 of the mold element 2, and a corresponding energy input is possible. The wall 2.In the exemplary embodiment, 1 comprises a first wall section extending in a first spatial plane and two further wall sections extending in a further spatial plane oriented (essentially) at right angles to the first spatial plane, wherein the flow channels extend both through the first wall section and through the further wall sections. As mentioned, the same applies to the second flow channels 4.2.

[0080] Returning to Fig. 5, it should be added that the wall 2.1 can be assigned a support structure 7, which supports the wall 2.1. The support structure 7 is arranged or formed on the surface of the wall 2.1 facing away from the mold cavity 3 and can be formed by one or more, e.g., linear or planar, support elements 7.1 or can comprise such elements that extend in one or more spatial planes or directions. The support structure 7 can thus have a lattice-like or grid-like configuration.

[0081] Not shown in the figures, but nevertheless conceivable, is that the temperature control device can have, in addition to respective first and second flow channels 4.1, 4.2, which, as described, enable flow-based heating and cooling of the mold cavity 3, at least one electrical heating element arranged or formed in the wall 2.1. The at least one electrical heating element, which can be a heating wire, for example, can serve, for example, to introduce additional thermal energy into the mold cavity 3 and thus into the particle foam material located therein in a locally targeted manner. In this way, for example, certain surface properties of the particle foam molded part to be produced or produced can be realized. The at least one electrical heating element can thus be arranged, for example, in a wall section of the wall 2 that laterally delimits the mold cavity 3.1 may be arranged or designed to realize certain surface properties in corresponding areas of the particle foam molded part.

[0082] The mold 1 is typically assigned a control device implemented in hardware and / or software for controlling the operation of the temperature control device. The control device is particularly configured to control the operation of the temperature control device for heating the mold cavity 3 dependently or independently of the operation of the temperature control device, e.g., for cooling the mold cavity 3. The control device can thus be configured to generate first control information for controlling the operation of the temperature control device for heating the mold cavity and, dependently or independently therefrom, second control information for controlling the operation of the temperature control device for cooling the mold cavity 3, and to use the control information as the basis for controlling the operation of the temperature control device.Controlling the operation of the temperature control device for heating the mold cavity 3 includes, in particular, controlling at least one parameter of a heating medium flowing through the first flow channels, in particular a relevant parameter influencing the heating performance, such as, for example, the pressure, the temperature, the flow rate. Similarly, controlling the operation of the temperature control device for cooling the mold cavity 3 includes, in particular, controlling at least one parameter of a cooling medium flowing through the second flow channels 4.2, in particular a relevant parameter influencing the cooling performance, such as, for example, the pressure, the temperature, the flow rate.

[0083] The molding tool element 2.1 can comprise at least one sensor element (not shown) configured to detect at least one parameter influencing the heating performance of the heating medium or of a heating medium flowing through the first flow channels 4.1 and / or at least one sensor element (not shown) configured to detect at least one parameter influencing the cooling performance of the cooling medium or of a cooling medium flowing through the second flow channels 4.2. Such parameters can include, in particular, the pressure, temperature, or flow velocity of the heating or cooling medium.

[0084] In embodiments in which the temperature control device additionally comprises at least one corresponding electrical heating element, the control device can in particular be configured to control the operation of the temperature control device for heating and / or cooling the mold cavity 3 dependently or independently of the operation of the at least one electrical heating element. In this way, the different heating principles can be used specifically to realize desired properties of a particle foam molded part to be produced. Analogous to the illustrations in FIGS. 1-3, FIGS. 8-11 show further schematically illustrated embodiments, from which it can be seen in particular that the flow channel structure 4 can form a gas injection device configured for injecting a gas into the mold cavity 3 or a component thereof, wherein one or more first flow channels 4.1 can be flowed through by a gas to be blown into the mold cavity 3, e.g. for demolding a particle foam molded part from the mold cavity 3, and / or the flow channel structure 4 - as shown in Figs. 8, 10 and 11 - comprises at least one third flow channel 4.3 arranged or formed in the wall 2.1, through which a gas to be blown into the mold cavity 3, e.g. for demolding a particle foam molded part from the mold cavity 3, can flow, and which has at least one flow channel section 4.3.1 opening into the mold cavity 3.

[0085] 8 - 11 that the flow channel structure 4 can form a gas extraction device designed to extract a gas from the mold cavity 3 or a component thereof, wherein one or more first flow channels 4.1 or one or more corresponding third flow channels 4.3 can be flowed through by a gas to be extracted from the mold cavity 3, e.g. for compressing and / or distributing particle foam material in the mold cavity 3 and / or for venting the mold cavity 3, and / or the flow channel structure 4 - as shown in Figs. 9 - 11 - at least one fourth flow channel 4.4 arranged or formed in the wall 2.1, which can be flowed through by a gas to be extracted from the mold cavity 3, e.g.for compressing and / or distributing particle foam material in the mold cavity 3 and / or for venting the mold cavity 3, and has at least one flow channel section 4.4.1 opening into the mold cavity 3.

[0086] A third and / or fourth flow channel configured to extract gas

[0087] 4.3, 4.4 may, although not shown in the figures, have smaller dimensions, ie in particular a smaller cross-sectional area, compared to a first and / or second flow channel 4.1, 4.2. The same applies to respective flow channel sections 4.3.1, 4.4.1 of respective third and / or fourth flow channels 4.3, 4.4.1 opening into the mold cavity 3.

[0088] 4.4, which can therefore also have smaller dimensions, ie in particular a smaller cross-sectional area, than the flow channel sections 4.4.1 of the respective first flow channels 4.1.

[0089] In this way, the flow channel structure 4 can perform alternative or additional functions compared to the embodiments according to Figs. 1 - 7, such as the compression, distribution or venting function mentioned.

[0090] From Figs. 8-11, it is also clear that corresponding third and / or fourth flow channels 4.3, 4.4 can be arranged or formed, for example, between adjacent first and second flow channels 4.1, 4.2. In particular, individual, several, or all third and / or fourth flow channels 4.3, 4.4 can be arranged or formed offset in at least one spatial direction from the respective first and / or second flow channels 4.1, 4.2.

[0091] For all embodiments, it further applies that the mold element 2 can be manufactured using an additive manufacturing process, in particular a powder-bed-based additive manufacturing process, such as a selective laser melting process, binder jetting process, etc., thus using 3D printing. In this way, the flow channels 4.1 - 4.4 can be formed in any configuration directly with the mold element 2.1, resulting in significant degrees of freedom with regard to design, construction, and production compared to conventional manufacturing processes.

[0092] The molding tool 1 is generally designed for producing technical components or component groups. In particular, technical components or component groups with a plate-like or plate-shaped basic shape are considered. Furthermore, in particular, components or component groups to be installed in a vehicle, in particular a motor vehicle, with a plate-like or plate-shaped basic shape are considered. A concrete example of a component or component group that can be produced using the molding tool 1 is a base body of a panel component, i.e. in particular a sun visor component. Corresponding panel components or sun visor components can be produced particularly practically using the molding tool 1 due to the properties of the particle foam material that can be processed with the molding tool 1.

[0093] The mold 1 shown in the figures can be used to implement a method for processing a particle foam material to produce a particle foam molded part. The method comprises, in particular, one, several, or all of the following steps: filling the mold cavity 3 with a particle foam material to be processed to produce a particle foam molded part; heating the particle foam material located in the mold cavity 3 by means of the flow channel structure 4 operated as a temperature control device; cooling and / or preheating and / or postheating the particle foam material and / or the particle foam molded part by means of the flow channel structure 4 operated as a temperature control device; demolding the particle foam molded part from the mold cavity 3.

[0094] The method may further comprise a step of blowing a gas, such as compressed air, into the mold cavity, e.g. for demolding a particle foam molded part from the mold cavity 3, e.g. by means of corresponding third flow channels 4.3, and / or a step of extracting a gas from the mold cavity, e.g. for compressing or distributing particle foam material in the mold cavity 3 and / or for venting the mold cavity 3, e.g. by means of corresponding third and / or fourth flow channels 4.3 4.4.

Claims

NSP RÜ THAT 1. Molding tool (1) for processing a particle foam material to produce a particle foam molded part, comprising: at least one molding tool element (2) which has at least one wall (2.1) which at least partially, optionally completely, delimits a molding tool cavity (3) of the molding tool (1), a flow channel structure (4) comprising several flow channels (4.1 - 4.4) through which a flow medium can flow, which has at least one first flow channel (4.1) arranged or formed in the wall (2.1) and through which a first flow medium can flow, wherein the at least one first flow channel (4.1) has at least one flow channel section (4.1.1) opening into the molding tool cavity (3) through which a flow medium can flow from the at least one first flow channel (4.1) into the molding tool cavity (3), and at least one in the wall (2.1) a second flow channel (4.2) arranged or formed, which can be flowed through by a second flow medium.

2. Molding tool according to claim 1, wherein the flow channel structure (4) forms a temperature control device or a component thereof for temperature control of the molding tool cavity (3), wherein the at least one first flow channel (4.1) is permeable by a heating medium, in particular a vaporous one, for heating the molding tool cavity (3), and / or wherein the at least one second flow channel is permeable by a cooling medium, in particular a liquid one, for cooling the molding tool cavity (3) or by a heating medium, vaporous or liquid, for heating the molding tool cavity (3).

3. Molding tool according to claim 1 or 2, wherein the flow channel structure (4) forms a gas injection device or a component thereof for injecting a gas into the molding tool cavity (3), wherein the at least one first flow channel (4.1) is permeable by a gas to be injected into the molding tool cavity (3), e.g. for demolding a particle foam molded part from the molding tool cavity (3), and / or wherein the flow channel structure (4) comprises at least one third flow channel (4.3) arranged or formed in the wall (2.1), which is permeable by a gas to be injected into the molding tool cavity (3), e.g. for demolding a particle foam molded part from the molding tool cavity (3), and has at least one flow channel section (4.3.1) opening into the molding tool cavity (3).

4. Molding tool according to one of the preceding claims, wherein the flow channel structure (4) forms a gas extraction device or a component thereof for extracting a gas from the molding tool cavity (3), wherein the at least one first flow channel (4.1) or a corresponding third flow channel (4.3) is permeable by a gas to be extracted from the mold cavity (3), e.g. for distributing particle foam material in the mold cavity (3), and / or wherein the flow channel structure (4) comprises at least one fourth flow channel (4.4) arranged or formed in the wall (2.1), which is permeable by a gas to be extracted from the mold cavity (3), e.g. for distributing particle foam material in the mold cavity (3), and has at least one flow channel section (4.4.1) opening into the mold cavity (3).

5. Molding tool according to one of the preceding claims, wherein the at least one first flow channel (4.1) and / or second flow channel (4.2) and / or third flow channel (4.3) and / or fourth flow channel (4.4) extends at least sectionally, optionally completely, in a straight line through at least one spatial plane through the wall (2.1).

6. Forming tool according to one of the preceding claims, wherein the at least one first flow channel (4.1) and / or second flow channel (4.2) and / or third flow channel (4.3) and / or fourth flow channel (4.4) extends at least sectionally, optionally completely, bent, curved or kinked in at least one spatial plane through the wall (2.1).

7. Molding tool according to one of the preceding claims, wherein the at least one first flow channel (4.1) and / or second flow channel (4.2) and / or third flow channel (4.3) and / or fourth flow channel (4.4) extends through the wall (2.1) in a first spatial plane and in a second spatial plane oriented perpendicular to the first spatial plane.

8. Molding tool according to claim 7, wherein the wall (2.1) has a first wall section extending in a first spatial plane and at least one further wall section extending in a further spatial plane oriented at an angle to the first spatial plane, wherein the at least one first flow channel (4.1) and / or second flow channel (4.2) and / or third flow channel (4.3) and / or fourth flow channel (4.4) extends through the first wall section and through the at least one further wall section.

9. Molding tool according to one of the preceding claims, wherein the at least one first flow channel (4.1) and / or second flow channel (4.2) and / or third flow channel (4.3) and / or fourth flow channel (4.4) extends through the wall (2.1) in several spatial planes, in particular parallel or inclined with respect to a reference plane of the molding tool cavity (3), and further in particular a base plane bounding the molding tool cavity on the bottom side.

10. Forming tool according to one of the preceding claims, wherein the at least one first flow channel (4.1) and / or second flow channel (4.2) and / or third flow channel (4.3) and / or fourth flow channel (4.4) has at least sectionally a round, rounded or angular cross-sectional geometry.

11. Molding tool according to one of the preceding claims, wherein the at least one flow channel section (4.1.1 , 4.3.1 , 4.4.1) opening into the molding tool cavity (3) of the at least one first flow channel or of the at least one third flow channel (4.3) and / or of the at least one fourth flow channel (4.4) has at least sectionally a round, rounded or angular cross-sectional geometry.

12. Forming tool according to one of the preceding claims, wherein the at least one first flow channel (4.1) and / or second flow channel (4.2) and / or third flow channel (4.3) and / or fourth flow channel (4.4) runs at least sectionally, optionally completely, in a spiral or helical winding manner through the wall (2.1).

13. Forming tool according to claim 12, wherein the at least two flow channels (4.1 - 4.4) each extend at least partially, optionally completely, in a helical or -shaped manner through the wall (2.1), wherein the at least two flow channels (4.1 - 4.4) form a double-helix or -shaped arrangement.

14. Molding tool according to one of the preceding claims, wherein at least two flow channels (4.1 - 4.4) are arranged at least sectionally in parallel.

15. Molding tool according to one of the preceding claims, comprising several first flow channels (4.1) and several second flow channels (4.2) and / or third flow channels (4.3) and / or fourth flow channels (4.4), which are arranged or formed at least partially in an alternating arrangement next to each other.

16. Forming tool according to one of the preceding claims, further comprising a temperature control device which has at least one electrical heating element arranged or formed in the wall (2.1).

17. Molding tool according to claim 2, comprising a control device for controlling the operation of the temperature control device, wherein the control device is configured to control the operation of the temperature control device for heating the molding tool cavity (3) depending on or independently of the operation of the temperature control device for cooling the molding tool cavity (3).

18. Molding tool according to claims 16 and 17, wherein the control device is configured to control the operation of the temperature control device for heating the molding tool cavity (3) and / or the operation of the temperature control device for cooling the molding tool cavity (3) depending on or independent of the operation of the at least one electrical heating element.

19. Forming tool according to one of the preceding claims, wherein the at least one forming tool element (2) is designed as a forming tool half, as a forming tool insert, as a slide or as a core.

20. Molding tool according to one of the preceding claims, wherein the at least one molding tool element (2) is manufactured in an additive manufacturing process, in particular a powder bed-based additive manufacturing process.

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