Abstract
The invention relates to a method for producing a fiber-reinforced, polymeric continuous profiled element (1), wherein the continuous profiled element (1), having preferably at least one hollow chamber (2, 2), comprises a core profile (10) which can be produced by means of a pultrusion process, and wherein during the pultrusion process at least one continuous strand having reinforcement fibers (5) is integrated into the polymer matrix (4) of the core profile (10). According to the invention, the curing of the core profile (10) is carried out by means of a dual-cure method.
Claims
1. A method for producing a fiber-reinforced polymeric continuous profile (1), wherein the continuous profile (1), preferably comprising at least one hollow chamber (2, 2), comprises a core profile (10) which is produced with the aid of a pultrusion process, and wherein at least one continuous strand having reinforcing fibers (5) is integrated into the polymeric matrix (4) of the core profile (10) during the pultrusion process, characterized in that the hardening of the core profile (10) takes place using a dual cure method.
2. The method according to claim 1, characterized in that the feed material (K1, K2) for producing the polymeric matrix (4) has a dynamic viscosity of 100-10,000 MPas, preferably 500-1000 MPas, at 20 C.
3. The method according to claim 1, characterized in that the feed material (K1, K2) for producing the core profile (10) comprises polythiols, methyl methacrylates, lactams or stabilized one-component systems, in particular stabilized thiols.
4. The method according to claim 1, characterized in that the dual cure method is made up of a UV cure and a heat cure.
5. The method according to claim 4, characterized in that the heat cure is downstream of the UV cure.
6. The method according to claim 1, characterized in that the core profile (10) is provided with an extruded outer, thermoplastic coating (12) immediately after being shaped.
7. The method according to claim 6, characterized in that the coating (12) is made from a polymer (15) adhering to the core profile (10), in particular a polyacrylate, a polyester or a polyamide.
8. The method according to claim 6, characterized in that color pigments (22) are added to the material (15) of the coating (12) before it is applied to the core profile (10).
9. The method according to claim 6, characterized in that the second curing process of the dual cure method is a heat cure, the input of heat required for this taking place by the application of the hot extrusion melt of the coating (12) to the core profile (10).
10. A continuous profile (1), produced by a method according to claim 1.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention will be explained in detail below with reference to a drawing representing only one exemplary embodiment. The figures show schematically:
[0019] FIG. 1: a method according to the invention for producing a hollow-chambered window profile;
[0020] FIG. 2a-c: hollow-chambered profiles produced according to the invention, for example by a method according to FIG. 1, in a cross-sectional illustration,
[0021] FIG. 3a, b: further embodiments of the teaching according to the invention and
DETAILED DESCRIPTION
[0022] FIG. 1 shows a method according to the invention for producing a continuous fiber-reinforced polymeric hollow-chambered window profile 1. The hollow-chambered profile 1 comprises a core profile 10 having a plurality of hollow chambers 2, 2 (see FIG. 2a-c), which is produced with the aid of a pultrusion process 3 at 80 to 240 C., preferably 120-200 C. During this pultrusion process 3, continuous glass reinforcing fibers 5 are integrated into the polymeric matrix 4 of the core profile 10, said fibers being firstly drawn off from rolls 6 and preheated in a preheating station 7. Using a pulling tool 8, the freshly produced core profile 10 is pulled out from the heated pultrusion die 9 in the production direction x over the continuous reinforcing fibers 5. The polymeric matrix 4 of this core profile 10 here is produced from low-viscosity components K1 and K2, which are hardened by two different curing mechanisms by way of a dual-cure method. The components K1 and K2 for producing the polymeric matrix 4 have a dynamic viscosity of 500-1000 MPas at 20 C. and comprise, for example, polythiols, methyl methacrylates, lactams, or stabilized thiols.
[0023] In the exemplary embodiment, the dual cure method is made up of a UV cure of the component K1 and a heat cure of the component K2, the heat cure being downstream of the UV cure. Initially, therefore, immediately after the impregnation of the reinforcing fibers 5 with the components K1 and K2, a UV cure of the component K1 takes place by appropriate irradiation 70, for example using a mercury vapor lamp or LED. As an alternative to the UV cure, an electron beam cure using an EBC source may also be performed by using appropriately curable materials for the component K1.
[0024] The core profile 10 produced by the pultrusion 3 is provided by way of a coextrusion 11, as it were, with an extruded outer coating 12 composed of an unreinforced polymer 15, e.g. a polyacrylate, a polyester or a polyamide, adhering to the core profile 10, to improve the surface quality of the hollow-chambered profile 1 after it has been shaped at a temperature of 160-300 C., preferably 200-260 C. In the exemplary embodiment according to FIG. 1, this coextrusion 11 takes place using an extruder 16 immediately following the pultrusion 3 without intermediate cooling. The coextrusion die 13 here is arranged immediately after the outlet of the die 9 for the pultrusion 3 and sheathes the core profile 10 online. In the exemplary embodiment, the second curing process of the dual cure method for hardening the component K2 is a heat cure, the input of heat required for this taking place by the application of the hot extrusion melt of the coating to the core profile 10. Consequently, therefore, in the exemplary embodiment the second step of the dual cure method for hardening the component K2 and the coextrusion 11 of the coating 12 are brought together to form a combined method step. Only then is the coextruded hollow-chambered profile 1 cooled in a cooling apparatus 14, e.g. a water bath. The production rate v for producing the hollow-chambered profile 1 is at least 2 m/min, e.g. 2-10 m/min.
[0025] FIGS. 2a to 2c show hollow-chambered window profiles 1 produced according to the invention, which can be produced by the method described in FIG. 1, for example. The enlarged cutout of FIG. 2a shows the reinforcing fibers 5 embedded in the thermoplastic matrix 4 of the core profile 10 (colored black in FIGS. 2a to 2c), as well as the coating 12, shown here with exaggerated thickness, composed of the coating material 15. The coating 12 has a layer thickness s of 0.1 to 1 mm, preferably 0.2 to 0.5 mm. The proportion by weight of the reinforcing fibers 5 in the core profile 10 is more than 80% in the exemplary embodiment. In the exemplary embodiment according to FIG. 2a, two further hollow chambers 2 are formed jointly by the core profile 10 comprising a plurality of hollow chambers 2, and the coating 12. Accordingly, in this exemplary embodiment, the coating 12 is applied only to some regions of the outer surface of the core profile 10; in the connecting regions 17 of the hollow chambers 2 formed jointly by core profile 10 and coating 12, no coating of the outer surface of the core profile 10 took place, since these connecting regions 17 are not outwardly visible. In all the exemplary embodiments according to FIGS. 2a to 2c, the hollow-chambered profiles 1 furthermore comprise functional elements 18, 18 in the form of receiving grooves for sealing elements and/or latching elements (not shown), the receiving grooves 18 in FIGS. 2a and 2b each being formed solely by the material 15 of the coating 12i.e., without core profile 10. In FIG. 2c, in contrast, the functional elements 18 are also each formed by a coated cross-sectional region of the core profile 10, i.e., the core profile 10 here contributes significantly to the shape of the functional elements. In FIGS. 2a to 2c, the hollow-chambered window profile 1 is in the form of a sash frame profile. Accordingly here, the core profile 10 has in each case a rebate base 19 for receiving at least one glass pane (not shown). In FIGS. 2b and 2c, the coating 12 is applied to almost the whole area of the outer surface of the core profile 10. Only the groove base of the right-hand receiving groove 18 in each case is formed solely by the core profile 10, this being applicable also to the exemplary embodiment according to FIG. 2a. Furthermore, in all three exemplary embodiments according to FIGS. 2a to 2c, protrusions 20 of a euro groove 21 of the hollow-chambered profile 1 for receiving locking elements (not shown) are formed only by the coating 12.
[0026] The hollow-chambered profiles 1 shown in FIGS. 2a to 2c may be appropriately colored by adding color pigments 22 to the material 15 of the coating 12 before it is applied to the core profile 10. Apart from the use of traditional white pigments 22, e.g. titanium dioxide, in particular color pigments 22 may also be used, which impart a true color to the coating 12 and lead, e.g., to a red, green, blue, grey, yellow, or even black coloring of the hollow-chambered profile 1. It is not shown in the exemplary embodiments, but is likewise possible within the scope of the invention, that the outer coating is applied to the core profile 10 as a liquid and/or powder and then hardened to form a lacquer coat.
[0027] In the exemplary embodiment according to FIG. 3a, the hollow-chambered window profile 1 is in the form of a core element which is provided on each of the inside and the outside with a casing 30, 30. These casings 30, 30 may each consist of aluminum, wood or likewise of plastics, and define the design of the overall profile made up of the elements 1, 30, 30. In the case of the formation of a door frame or window frame having, e.g., four corners, there is no need for a corner connection of each of the casings 30, 30 to one another, since the corner connections of the overall frame are produced by corresponding corner welds of the mitered hollow-chambered window profiles 1 (i.e., in this case, the core elements).
[0028] In the exemplary embodiment according to FIG. 3b, a rectangular hollow-chambered frame 100 of a window profile or door profile is formed by first appropriately mitering a hollow-chambered profile 1 according to the invention at each of the corners 50 such that only the outer wall 60 remains there. By bending the remaining outer wall 60 at each of the corners 50, the hollow-chambered frame 100 is then formed. The entire hollow-chambered frame 100 here (conventionally made up of four profiles) thus consists of a single hollow-chambered profile 1, which is connected, preferably welded, to itself at one of the corners to form the closed frame 100. It is advantageous here that the reinforcing fibers 5 extend all the way round in the outer wall 60 and thus contribute to very high stability.
