CN102387909A - Method for producing a highly rigid, hybrid, continuous profiled element, and highly rigid, hybrid, continuous profiled element - Google Patents

Abstract

The invention relates to a method for producing a high-strength, hybrid continuous profiled element. According to said method, roving (1) containing reinforcing fibres is transformed into a profiled shape, and the profiled roving is coated by a plastic layer (3) by means of an extrusion process. The invention also relates to a highly rigid, hybrid continuous profiled element.

Description

Method for producing highly rigid, hybrid continuous profiles and highly rigid, hybrid continuous profiles

technical field

The invention relates to a method for producing highly rigid, hybrid continuous profiles.

Background technique

Different manufacturing methods have been established in the past for the manufacture of fiber composite materials. These are on the one hand high-pressure methods, in particular injection moulding, extrusion and punching, and on the other hand low-pressure methods such as RTM (resin transfer molding) and retort methods. High-pressure methods are distinguished in particular by the high production speeds possible for this purpose, while low-pressure methods make it possible to produce components with high mechanical strength. Such component properties cannot, or can only be provided with considerable effort, by means of high-pressure methods. In the low-pressure method, the necessary long hardening times of the plastics used here are disadvantageous, since this reduces the yield and thus increases the production costs of components of this type. It was thus established when compared with the methods known from the prior art that on the one hand large-scale production is required and on the other hand the requirement of a very high mechanical load-bearing capacity of the finished component is mutually excluded. In low-pressure methods, due to the curing time of the thermosetting resin systems used, the cooling durations which determine the cycle times are considerably longer than in the case of thermoplastics, which can be processed in high-pressure methods. Furthermore, low-pressure methods generally require discontinuous production, which likewise has a negative impact on production costs.

Contents of the invention

Based on the stated background, the invention is based on the object of providing a method which can produce high load-bearing structural profiles at high production speeds.

According to the invention, said object is achieved by a method for the production of highly rigid, hybrid continuous profiles, in which rovings containing reinforcing fibers are fed into the forming structure and then, by means of an extrusion process, coated with a plastic layer Roving for wrap molding.

According to the invention, a usually thermoplastic plastic layer is extruded, wherein the mechanical strength of the profile is provided by shaped rovings containing reinforcing fibers, which are preferably completely sheathed by the extruded plastic. As reinforcing fibers, glass fibers and/or carbon fibers are preferably used. In this case, the rovings are usually also present as a continuous product, so that the reinforcement layer produced with the aid of the rovings is suitable for producing a continuous profile. "Continuous" means that the length of the corresponding object is a multiple of its other dimensions, so that a continuous manufacturing process is possible. With the aid of the teaching according to the invention, it is possible to combine high production speeds, which can be produced by means of the extrusion process, with a high mechanical load-bearing capacity of the components produced therefor.

Preference is given to using rovings which, in addition to reinforcing fibers, also contain plastic fibers. In the mixed roving, the plastic fibers can likewise have thermoplastic properties. In a preferred embodiment of the invention, the plastic fibers are at least partially melted during the production process in order to increase the rigidity of the roving during shaping. This can be achieved, for example, by simultaneous preheating of the roving during the forming process of the roving layer.

Preference is given to using rovings, the fibers of which are crossed, for example in the form of woven rovings. The rovings can be formed as a fabric. In particular, the fibers can be oriented relative to one another such that they together form a rhomboid structure. The roving thus has a flat composite structure which is highly load-bearing in a plane in any direction, so that the roving can also be processed in a very simple manner. Furthermore, the plastic layer covering the rovings can likewise contain reinforcing fibers, for example glass fibers and/or carbon fibers, in order to further increase the strength of the combined continuous profile.

The shaping of the roving can take place, for example, in a texturing device. In this case, an open profile consisting of rovings is usually produced. As an alternative to this, however, it is also possible to shape the rovings by applying them, preferably winding or weaving them, onto the plastic extrusion profile. In this case, there is at least a three-layer structure with the built-in extruded profile, the roving layer as the middle layer and the wrapping plastic layer as the outer layer. Accordingly, profile layers formed from rovings are included here. It is generally sufficient here that the preheating of the roving, which is necessary for melting the thermoplastic fibers in the roving, takes place by contact with the still hot plastic extrusion profile. According to a special embodiment of the invention, the plastic extruded profile also contains reinforcing fibers, for example glass fibers and/or carbon fibers, wherein short fibers and/or continuous fibers can be used here.

The hybrid continuous profile according to the invention can be formed as an open profile and as a closed profile. In general, a wide variety of geometries can be realized by means of the method according to the invention.

Furthermore, the subject of the invention is a highly rigid, hybrid continuous profile according to claim 10 . Preferred embodiments of the profile are specified in subclaims 11 to 14 .

Particular areas of application of the concept according to the invention are, for example, cooling plant frames, cover profiles, sliding rails, LKW (truck truck) construction, aircraft construction, frame profiles for air-conditioning systems, window profiles, piping systems and automobile construction, in particular are structural components, for example, as a replacement for metal profiles or organometallic sheets.

Description of drawings

The invention is explained below with the aid of a drawing showing only one exemplary embodiment, in which it is shown schematically:

FIG. 1 shows a first variant of the method according to the invention for producing a highly rigid, hybrid continuous profile;

Figure 2 shows an alternative manufacturing method; and

FIG. 3 shows a cross-section through a highly rigid, hybrid continuous profile according to the invention.

Detailed ways

FIG. 1 shows a method according to the invention for producing a highly rigid hybrid continuous profile. In this case, rovings 1 containing glass fibers are fed into a three-dimensionally shaped structure. Instead of or in addition to glass fibers, carbon fibers can also be used. The formed roving 1 is then completely wrapped with a thermoplastic plastic layer 3 by means of an extrusion process 2 . In addition to glass fibers, the rovings 1 used additionally have plastic fibers made of thermoplastic material. The roving 1 is formed by winding or weaving it on a plastic extrusion profile 5 produced by means of a further extrusion process 4 and consisting of a thermoplastic reinforced with glass fibers. Thus, a closed contour of the reinforcement layer 6 composed of rovings 1 of the continuous profile to be produced is produced. As a result of the contact of the mixed rovings 1 with the still hot extruded profile 5 , the plastic fibers are partially melted, so that the rigidity of the rovings 1 increases during shaping and the connection effect to the extruded profile 5 is additionally enhanced. A roving 1 is used, the fibers of which are crossed so that there is a flat composite structure. In the exemplary embodiment, the outer thermoplastic outer plastic layer 3 has no additional reinforcement material and therefore does not contain, in particular, glass fibers and/or carbon fibers. The plastic extruded profile 5 is designed as a closed hollow profile which has a plurality of ribs 7 and thus has a limited number of hollow chambers 8 . During the continuous extrusion of the inner profile 5 , the roving 1 is wound by a roller 9 whose axis x is oriented at least parallel to the extrusion direction. Then, in a second extrusion process 2 , the wound roving 1 is wrapped with an outer plastic layer 3 .

In the embodiment according to FIG. 2 , the inner plastic extruded profile is omitted, and the roving 1 is wound by a roller 9 whose axis x' is oriented at least substantially perpendicularly to the extrusion direction. The tape-shaped roving 1 is continuously withdrawn from said roll 9 and firstly undergoes a texturing process and a preheating process. In order to deform the roving 1 into a shaped structure, a texturing device 10 is used in which the mixed roving 1 consisting of glass fibers and plastic fibers is simultaneously preheated. Due to the preheating, the plastic fibers are at least partially melted in order to increase the rigidity of the roving 1 during shaping. The roving profile 6 obtained in this case has an open profile. Similar to the method shown in FIG. 1 , the shaping process of the roving 1 is followed by wrapping of the roving by means of a pressing step. In this case, thermoplastics reinforced with glass fibers can be used as extrusion material. It can be seen from FIG. 2 that in the extrusion process 2 not only the overwrapping of the roving layer takes place, but also that the cavity 11 formed by the roving 1 by the profile contour is at least partially filled by the extruded profile. In the exemplary embodiment described, a hollow chamber profile, which is also hollow but closed to the outside, is introduced into the cavity 11 by extrusion, with a plurality of ribs 7 .

As glass fibers mixed into the plastic extruded profile 5 or the plastic layer 3 , short glass fibers and/or continuous fibers can be used. Figure 3 shows a cross-sectional view of a highly rigid, hybrid continuous profile according to the invention. The continuous profile has a reinforcement layer 6 consisting of shaped rovings 1 containing glass fibers and a plastic layer 3 which completely surrounds the reinforcement layer 6 . The roving 1 additionally contains at least partially melted plastic fibers. The reinforcement layer 6 is applied to, preferably wound on, the plastic extruded profile 5 , the so-called core component, thus enabling the shaping of the roving 1 . Accordingly, the profile shown in FIG. 3 is produced according to the method according to FIG. 1 . The plastic layer 3 , also referred to as the main component, completely surrounds the reinforcement layer 6 and consists of thermoplastic, preferably unreinforced plastic. Furthermore, it can be seen from FIG. 3 that the reinforcement layer 3 has reinforcement ribs 7 with inner cavities 8 . The plastic extruded profile 5 (core component) is reinforced with short glass fibers and/or continuous fibers. In particular PP (polypropylene), PA6 (polyamide) and PVC (polyvinyl chloride) granules are suitable as thermoplastics for the plastic extrusion profile 5 .

Claims (14)

1. method that is used to make continuous section bar high rigidity, that mix,

Wherein, the rove that will comprise fortifying fibre is delivered in the molding structure, and

Then, wrap up said in type rove by extrusion with plastic layer.

2. the method for claim 1 is characterized in that, uses rove, and said rove also comprises plastic optical fibre except fortifying fibre.

3. method as claimed in claim 2 is characterized in that said plastic optical fibre is melted at least in part, so that improve the rigidity of said rove when moulding.

4. like the described method of one of claim 1 to 3, it is characterized in that, use rove, the cross fibers of said rove.

5. like the described method of one of claim 1 to 4, it is characterized in that said plastic layer comprises fortifying fibre equally, preferred glass fibers and/or carbon fiber.

6. like the described method of one of claim 1 to 5, it is characterized in that the moulding in anamorphic attachment for cinemascope of said rove.

7. like the described method of one of claim 1 to 5, it is characterized in that the moulding of said rove is preferably twined or is woven on the extruded in plastic section bar and carry out through it is applied.

8. method as claimed in claim 7 is characterized in that, said extruded in plastic section bar comprises the fortifying fibre that is preferably glass fibre equally.

9. like the described method of one of claim 1 to 8, it is characterized in that said continuous section bar constitutes the section bar of opening or the hollow profile of sealing.

10. a continuous section bar high rigidity, that mix has:

The back-up coat of forming by in type, as to comprise fortifying fibre rove (1) (6); With

Wrap up the plastic layer (3) of said back-up coat (6).

11. continuous section bar as claimed in claim 10 is characterized in that, said rove (1) additionally comprises the plastic optical fibre that at least partly is melted.

12. like claim 10 or 11 described continuous section bars, it is characterized in that said back-up coat (6) is applied to, preferred twine ground or be woven on the extruded in plastic section bar (5).

13., it is characterized in that said plastic layer (3) and/or said extruded in plastic section bar (5) comprise the fortifying fibre that is preferably glass fibre equally like the described continuous section bar of one of claim 10 to 12.

14., it is characterized in that said continuous section bar has the reinforcement (7) that has boring chamber (8) like the described continuous section bar of one of claim 10 to 13.

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