Method and device for producing three-dimensional molded parts and corresponding molded part

A method for producing three-dimensional molded parts made of fiber material under the use of a mold comprising a bottom mold, whose inner side defines the contours of the bottom side of the molded part, and at least one top mold, whose inner side defines the contours of the top side of the molded part, with at least one of the bottom mold and the top mold featuring holes for the passage of air, said method comprising:

• blowing-in fibers by an air current into an intermediate space between the bottom mold and a first temporary top mold;
• depositing fibers on the inner sides of the bottom mold and the first temporary top mold until the mold is filled, whereby an intermediate preform is formed from fiber material;
• removing the first temporary top mold;
• placing a second temporary top mold;
• blowing-in additional fibers by an air current into an intermediate space between the bottom mold and the second temporary top mold;
• depositing additional fibers on the top side of the intermediate preform and the inner side of the second temporary auxiliary top mold, whereby a preform made of fiber material is formed;
• removing the second temporary top mold;
• and
• placing the top mold, whereby the preform is compacted.

A method for producing three-dimensional molded parts made of fiber material under the use of a mold comprising a bottom mold, whose inner side defines the contours of the bottom side of the molded part, and at least one top mold, whose inner side defines the contours of the top side of the molded part, with at least one of the bottom mold and the top mold featuring holes for the passage of air, said method comprising:

• blowing-in of fibers by an air current into an intermediate space between the bottom mold and a temporary top mold until a predetermined value of air pressure is reached in the mold;
• depositing fibers on the inner sides of the bottom mold and the temporary auxiliary top mold until the mold is filled, whereby a preform is formed from fiber material;
• removing the temporary top mold;
• placing the top mold, whereby the preform is compacted;
• connecting the fibers by a mixed-in bonding agent;
• and
• heating the preform by one of heating the closed shape and causing hot air to flow through the mold, whereby a permanent connection of the fiber material is generated through reaction of the bonding agent and the preform is solidified into a molded part.

A device for producing three-dimensional molded parts made of fiber material, the device having a mold comprising;

• at least a first mold part and a second mold part, an inner side of the first mold part defining a first side of the three dimensional part to be molded, and an inner side of the second mold part determining the contours of a second side of the three dimensional part to be molded;
• at least one of the first and second mold parts includes holes for the passage of air;
• and
• at least one auxiliary mold part adapted for connecting with the first mold part in place of at least the second mold part, and having an inner side that is different from at least the contour of the second side of the part to be molded;
• wherein the mold includes at least one inflow opening for receiving blown fiber material.