Hybrid injection molding cell

具有“热塑性塑化单元”、“热固性塑化单元”和“泡沫塑化单元”三种可任意组合的模块，以及直接从原模具中集成金属结构元件的可能性，即通过注塑金属玻璃的可能性，所应用的双组份混合注塑单元在混合工艺组合中提供了独特的自由度。因此，这种混合注射成型电池可以将各种金属、纤维增强和纺织品、扁平半成品以及模压或成型的金属或塑料部件组合在一起，从而产生用于广泛应用的混合轻质结构（例如，用于航空航天的高温热塑性金属混合材料，用于电动汽车的屏蔽电池外壳等）。从而能够深入分析这些结构的工艺-结构-性能关系。其中一个重点是上述工艺路线的杂交，以生产具有相对较大代表性表面的杂交材料。来自整个塑料金字塔的塑料（从标准热塑性塑料，如PE和PP，到结构热塑性塑料，如PA，再到高温热塑性塑料，如PPS）被用作聚合物材料基础，这意味着加工/质量温度高达400°C。样品/组件斑块的投影面积可达50,000 mm²，这需要在850 bar的最大空腔压力下最小4,000 kN的夹紧力。其他混合组件包括金属板和所谓的有机板。为了能够以简单的方式手动插入这些部件并安全地拆卸组件，夹紧单元将被垂直设计。为了进一步提高混合动力部件复杂制造过程的工艺可靠性和可重复性，预计将采用自动化搬运系统和导轨进料系统。进一步的要求是金属玻璃加工系统的集成，作为混合组件，一方面具有高机械性能，另一方面-关于未来的研究领域-允许新的材料组合。为了增加不同基质系统（热固性和热塑性）与钢/有机板之间的附着力，在控制系统中设置了预热站，以确保整个工艺流程的顺畅和协调。为了绘制和分析注塑工艺参数和连接的外围设备（例如处理系统或预热站），系统必须能够记录测量数据，并将其传递给其他系统组件和工艺设置参数。这样创建的数据库也应该可用于过程和结构模拟。

With the modules "thermoplastic plasticizing unit", "thermoset plasticizing unit" and "foam plasticizing unit", which can be combined in any way, and the possibility of integrating metal structural elements directly from the original mold, i.e. through the possibility of injection molding metallic glasses, the 2-component hybrid injection molding cell applied for offers unique freedom in hybrid process combination. This hybrid injection molding cell thus enables the combination of a wide variety of metallic, fiber-reinforced and textile, flat semi-finished products and molded or formed metal or plastic components to generate hybrid lightweight structures for a wide range of applications (e.g. high-temperature thermoplastic-metal hybrids for aerospace, shielded battery housings for electromobility, etc.), thus enabling the in-depth analysis of the process-structure-property relationships of these structures. One focus is on the hybridization of the aforementioned process routes to produce hybrid materials with comparatively large, representative surfaces. Plastics from the entire plastic pyramid (from standard thermoplastics such as PE and PP, to structural thermoplastics such as PA, to high-temperature thermoplastics such as PPS) are used as the polymeric material basis, implying a processing/mass temperature of up to 400 °C. The projected area of the samples/component plaques is to map up to 50,000 mm², which requires a clamping force of min. 4000 kN at a maximum cavity pressure of 850 bar. Other hybrid components to be used include metal sheets and so-called organic sheets. In order to be able to insert these manually in a simple manner and remove the components safely, the clamping unit will be designed vertically. To further increase the process reliability and reproducibility of the complex manufacturing process for the hybrid components, an automated handling system and feeding via a rail system is foreseen. A further requirement is the integration of a system for processing metallic glasses, which, as hybrid components, on the one hand have high mechanical properties and on the other hand - with regard to research fields of the future - allow novel material combinations. In order to increase the adhesion between the different matrix systems (thermoset and thermoplastic) with the steel/organo sheets, a preheating station is provided in the control system to ensure a smooth and coordinated overall process flow. In order to map and analyze the injection molding process parameters and the connected peripherals (e.g. handling system or preheating station), the system must be able to record measurement data, pass it on to other system components and process setting parameters. The database thus created should also be available for process and structure simulation.