Thermoforming with Integrated Design Elements

在热成形过程中，热塑性薄板被成形成三维零件。成型过程通常通过施加压力差（真空和/或压缩空气）和/或借助拉伸辅助工具使用单侧工具进行。热成型通常用于生产包装制品，但也用于生产技术部件。因此，热成型工艺是与注射成型竞争的。然而，与注射成型相比，热成型仍有一些缺点。与注射成型相比，热成型过程的设计自由度受到限制。使用热成型工艺，只能生产没有功能元件（例如肋、螺杆、卡箍）的壳形零件。功能元件只能通过进一步的加工步骤来连接，例如焊接或粘合。然而，一项新的研究项目，集成设计元素的热成型，使得将功能元素集成到热成型过程中成为可能。通过此流程集成，可以省去后续的设计元素连接步骤。在集成设计元素的热成型过程中，首先必须在模具中放置插入件。然后板材可以成形，同时焊接到插入件上。这在插入件和热塑性塑料片材之间建立了紧密的连接。在这个研究项目中，必须研究热成型过程中与集成设计元素的基本材料关系。这将有助于理解这个新的过程。基于这些发现，还将开发过程建模。本研究项目的目的是研究热成形过程中单个工艺参数及其对焊缝质量的影响。此外，研究结果必须用于检查和改进描述焊接过程作用机制的现有模型。

During the thermoforming process thermoplastic sheets are formed into three-dimensional parts. The forming process is usually carried out using a one-sided tool by applying pressure differences (vacuum and/or compressed air) and/or by means of stretching aids. Thermoforming is usually used to produce packaging articles but also for producing technical components. Therefore, the thermoforming process stays in competition with injection molding. However, thermoforming still has some disadvantages compared to injection molding. In comparison to injection molding, the freedom of design in the thermoforming process is limited. With the thermoforming process only shell-shaped parts without functional elements (e.g. ribs, screw bosses, snap-fits) can be produced. Functional elements can only be attached by a further processing step, such as welding or gluing. Nevertheless, a new research project, thermoforming with integrated design elements, makes it possible to integrate functional elements into the thermoforming process. Through this process integration, the subsequent step of joining design elements can be saved. During thermoforming with integrated design elements, first an insert must be placed in the mold. Afterwards the sheet can be formed and at the same time welded to the insert. This creates a cohesive connection between the insert and the thermoplastic sheet.Within this research project, the basic material relationships for the thermoforming process with integrated design elements have to be investigated. This will help to understand this new process. Based on these findings, a process modeling will also be developed. The aim of this research pro-ject is to investigate the individual process parameters and influences on the quality of the welded seam during thermoforming with integrated design elements. In addition, the results have to be used to check and enhance existing models for describing the acting mechanisms of welding processes.