METHOD FOR PRODUCING AN AT LEAST PARTIALLY CONTOURED, FIBRE REINFORCED PLASTIC PROFILE, A CONTOURED, FIBRE REINFORCED PLASTIC PROFILE AND ITS USE

Abstract

A method for producing a partially contoured, fiber-reinforced plastic profile includes providing a plurality of first reinforcing fibers. The first reinforcing fibers are combined to produce a uni-, bi-, or tridirectional fiber bundle. The fiber bundle is impregnated with a first plastic matrix. The impregnated fiber bundle is supplied to a unit for at least partial shaping or for at least partial shaping and at least partial curing of the first plastic matrix to produce a fiber-reinforced plastic base element. Second reinforcing fibers are provided for at least partial application to the fiber-reinforced plastic base element. The fiber-reinforced plastic base element is provided with the second reinforcing fibers for at least partial fiber-reinforced profiling and/or shaping to produce an at least partially contoured, fiber-reinforced plastic strand and the at least partially contoured, fiber-reinforced plastic strand is cut to produce an at least partially contoured, fiber-reinforced plastic profile.

Claims

1.-18. (canceled)

19. A method for producing an at least partially contoured, fiber-reinforced plastic profile comprising: providing a plurality of first reinforcing fibers, combining the first reinforcing fibers to produce a uni-, bi-, or tridirectional fiber bundle, impregnating the fiber bundle with a first plastic matrix, performing at least partial shaping or at least partial shaping and at least partial curing of the first plastic matrix to produce a fiber-reinforced plastic base element, providing a plurality of second reinforcing fibers for at least partial application to the fiber-reinforced plastic base element, supplying the fiber-reinforced plastic base element provided with the second reinforcing fibers to a unit for at least partial fiber-reinforced profiling and/or shaping to produce an at least partially contoured, fiber-reinforced plastic strand, and cutting the at least partially contoured, fiber-reinforced plastic strand to produce an at least partially contoured, fiber-reinforced plastic profile, wherein the second reinforcing fibers are shorter in length than the first reinforcing fibers and are provided in the form of short and/or long fibers, wherein the at least partial profiling and/or shaping is carried out in a profiling/shaping unit.

20. The method of claim 19, wherein short and/or long fibers are applied wet as a mixture of short and/or long fibers and a second plastic matrix by scattering and/or spraying.

21. The method claim 19, wherein the fiber-reinforced plastic base element is fed through an impregnation unit that is filled with a mixture of short and/or long fibers and a liquid second plastic matrix in order to apply short and/or long fibers at least partially impregnated to the fiber-reinforced plastic base element.

22. The method claim 19, wherein after application of the second reinforcing fibers, the fiber-reinforced plastic base element is supplied to an electrostatic charging unit for specified orientation of the reinforcing fibers.

23. The method of claim 19, wherein curing of the second reinforcing fibers impregnated with a second plastic matrix is carried out during or after the at least partial profiling and/or shaping in order to produce the at least partially contoured, fiber-reinforced plastic strand.

24. The method of claim 19, wherein at least partial surface structuring is carried out on the at least partially contoured, fiber-reinforced plastic strand or the at least partially contoured, fiber-reinforced plastic profile, during or after the at least partial profiling and/or shaping, to produce the at least partially contoured, fiber-reinforced plastic strand.

25. The method of claim 19, wherein a core material is provided that is supplied together with the first reinforcing fibers to the unit for combining the first reinforcing fibers to produce the fiber bundle, wherein the core material is essentially completely enclosed by the reinforcing fibers in the longitudinal direction or is subsequently removed.

26. The method of claim 19, wherein the contoured, fiber-reinforced plastic strand is curved during or after curing or the contoured, fiber-reinforced plastic profile is subsequently curved.

27. The profiled, fiber-reinforced plastic profile produced in accordance with the method of claim 19, comprising a uni, bi- or tridirectional-fiber-reinforced plastic base element with an attached fiber-reinforced profiling, wherein the profiling contains short and/or long fibers, wherein the profiling is configured as a rib structure that is configured non-circumferentially around the plastic base element, a hemispherical structure, or a lens structure.

28. The plastic profile of claim 27, wherein the fiber-reinforced plastic base element has a round, square, rectangular, star-shaped, or lens-shaped cross-section, wherein the cross-section is of a constant or variable length.

29. The plastic profile of claim 27, wherein the profiling is of a constant or variable length.

30. The plastic profile of claim 27, wherein the fiber-reinforced plastic profile is a solid or hollow profile and/or as a hybrid profile composed of at least two different materials.

31. The plastic profile of claim 27, wherein the first reinforcing fibers are one or more of glass fibers, carbon fibers, ceramic fibers, basalt fibers, aramid fibers, flax fibers, hemp fibers, and plastic fibers.

32. The plastic profile of claim 27, wherein the second reinforcing fibers are one or more of glass fibers, carbon fibers, basalt fibers, aramid fibers, flax fibers, hemp fibers, metal fibers, and plastic fibers.

33. The plastic profile of claim 27, wherein the first and/or second plastic matrix is composed of a thermoplastic or a duroplast.

34. The plastic profile of claim 27, wherein the plastic profile has a connection area at one end or at both of its ends.

35. The fiber-reinforced plastic profile of claim 27 configured as a reinforcing bar.

36. An assembly comprising a first and a second fiber-reinforced plastic profile according to claim 27 connected to each other at their ends via a connecting element in a positive locking or non-positive locking manner.

37. The method of claim 19, wherein short and/or long fibers are applied dry as a mixture of short and/or long fibers and then impregnated with a second plastic matrix.

38. The method of claim 19, wherein the first reinforcing fibers are long and/or continuous fibers.

39. The method of claim 19, wherein the at least partial curing occurs under heating.

Description

[0037] In the following, the invention is explained in greater detail by means of a drawing depicting examples. The same components are indicated using the same reference numbers. The figures show the following:

[0038] FIG. 1): an example of a production device for carrying out a method according to the invention for the continuous production of a contoured, fiber-reinforced plastic profile in a schematic view,

[0039] FIG. 2a, b, c): a first example of a contoured, fiber-reinforced plastic profile according to the invention in a schematic top and side view and a section through A-A,

[0040] FIG. 3a, b, c): a second example of a contoured, fiber-reinforced plastic profile according to the invention in a schematic top and side view and a section through A-A,

[0041] FIG. 4a, b, c): a third example of a contoured, fiber-reinforced plastic profile according to the invention in a schematic top and side view and a section through A-A,

[0042] FIG. 5a, b, c): a fourth example of a contoured, fiber-reinforced plastic profile according to the invention in a schematic top and side view and a section through A-A,

[0043] FIG. 6): an example of connecting a plurality of contoured, fiber-reinforced plastic profiles according to the invention to one another.

[0044] FIG. 1 shows an example of a production device for carrying out a method according to the invention for the continuous production of a contoured, fiber-reinforced plastic profile (1, 1, 1, 1) in a schematic view. First, a plurality of first reinforcing fibers (2), preferably long or continuous fibers, which in particular are wound onto a plurality of rollers (2.1), are provided, which for example are arranged in a multi-level fiber rack or unwinding units (2.2) for the purpose of unwinding. As first reinforcing fibers (2), one can use glass fibers, carbon fibers, ceramic fibers, basalt fibers, aramid fibers, flax fibers, hemp fibers, plastic fibers or mixtures thereof. The first reinforcing fibers (2) can also be processed in the form of textile strips. The first reinforcing fibers (2) are unwound and continuously supplied to a unit (3) for combining the reinforcing fibers (2) in order to produce a fiber bundle (4). By means of one or a plurality of fiber guides (3.1), the reinforcing fibers (2) are combined into a fiber bundle (4). The reinforcing fibers (2) combined into a fiber bundle (4) are continuously supplied to a unit (5) for impregnating the fiber bundle (4) with a first plastic matrix, which is connected to a unit (6) for providing the first plastic matrix. Depending on the matrix material to be produced, whether a duroplast or a thermoplastic, a mixture of two matrix systems (6.1, 6.2) can also be provided in the unit (6). The fiber bundle (4) is completely impregnated in the unit (5). The impregnated fiber bundle is then continuously supplied to a unit (7) for at least partial shaping or for at least partial shaping and at least partial, preferably complete curing of the first plastic matrix in order to produce a fiber-reinforced plastic base element (8). The unit (7) is preferably a heated shaping unit, so that in addition to setting the geometry of the fiber-reinforced plastic base element to be produced (8), in particular its cross-section, which can be configured to be round, square, rectangular, star-shaped, or lens-shaped and as needed can have a constant or variable length, partial, preferably complete curing of the first plastic matrix also takes place by heating, without requiring the provision of further heating/curing units, such as for example continuous furnaces arranged downstream.

[0045] After this, second reinforcing fibers (9) in the form of short and/or long fibers are provided for at least partial application to the fiber-reinforced plastic base element (8). As second reinforcing fibers (9), one can use glass fibers, carbon fibers, basalt fibers, aramid fibers, flax fibers, hemp fibers, ceramic fibers, plastic fibers, metal fibers or mixtures thereof. For example, the second reinforcing fibers (9) are first locally or completely applied in dry form to the fiber-reinforced plastic base element by scattering and/or spraying in a unit (11). The unit (11) is connected to a unit (10) for providing a second plastic matrix that is used for impregnating the second reinforcing fibers (9), which have been applied dry to the fiber-reinforced plastic base element (8). The impregnated reinforcing fibers serve as a material for the profiling to be produced. Depending on the matrix material to be produced, whether a duroplast or a thermoplastic, a mixture of two matrix systems (10.1, 10.2) can also be provided in the unit (10). Alternatively, the second reinforcing fibers (9) can be applied wet as a mixture of reinforcing fibers and a second plastic matrix by scattering and/or spraying in a unit (11). The application can be carried out locally, in particular to the areas in which partial profiling takes place on the fiber-reinforced plastic base element (8), or the wet reinforcing fibers are applied to the entire surface of the fiber-reinforced plastic base element (8). The wet reinforcing fibers provide the material for producing the profiling, so that the layer thickness applied depends locally or completely on the final geometry to be produced. The unit (11) can for example comprise an electrostatic charging unit (12) for orienting the reinforcing fibers (9) and/or a stripping unit (12) for setting the optimum amount of the mixture of reinforcing fibers and the plastic matrix.

[0046] The fiber-reinforced plastic base element (8) provided with the second reinforcing fibers (9) is continuously supplied to a unit (13) for at least partial fiber-reinforced profiling and/or shaping in order to produce an at least partially contoured, fiber-reinforced plastic strand (14). As the profiling and/or shaping is carried out on the substantially moved plastic base element (8), different devices can be used as profiling/shaping units (13). For example, a co-moving press unit, which can only profile respective sections of the plastic base element (8) provided with the reinforcing fibers impregnated with the second plastic matrix (9), can be used. The mobile arrangement thus allows discontinuous production of a profiling (1.1, 1.1, 1.1, 1.1) on the continuously moved plastic base element (8). As a further example, an actively or passively driven roller unit, for example with two opposing rollers that form a gap through which the fiber-reinforced plastic base element provided with reinforcing fibers (8) is fed, can be used. In the rollers, profiling with a correspondingly introduced negative mold is provided. The profiling (1.1, 10.1, 1.1, 1.1) can also be produced in stages, for example using rollers (13) arranged in series. A shaping chain unit that at least partially encloses the plastic base element can also produce a profiling with a correspondingly introduced negative mold. For example, if the chain unit is actively driven, one can dispense with additional draw-off/drive units (15), so-called pullers, in the pultrusion method. The unit (13) for at least partial fiber-reinforced profiling and/or shaping in order to produce an at least partially contoured, fiber-reinforced plastic strand (14) is preferably heated in order to carry out partial, preferably complete curing of the plastic base element and the profiling (profiling layer), or the profiling (profiling layer) alone, without requiring that further heating/curing units, such as for example continuous furnaces arranged downstream, be provided. At least one draw-off/drive unit (15) is used as a feed unit, which is movable in or opposite to the draw-off direction of the plastic strand (14), symbolized by the arrow shown, which represents an alternating movement.

[0047] Finally, the at least partially contoured, fiber-reinforced plastic strand (14) is cut off in a cutting unit (16), and an at least partially contoured, fiber-reinforced plastic profile (1, 1, 1, 1) is provided.

[0048] Because of the use of short and/or long fibers (9) to reinforce the profiling geometry instead of profiles around which continuous fibers are wound, there are virtually no limits on the profiling (1.1, 10.1, 1.1, 1.1), as shown by way of example in FIGS. 2 through 5. Furthermore, in the use of short and/or long fibers (9) to reinforce the profiling geometry instead of profiles around which continuous fibers are wound, the reinforcing fibers (9) can be arranged in a manner appropriate for the load path. The contoured, fiber-reinforced plastic profiles (1, 1, 1, 1) are preferably used in construction as reinforcing bars, in particular in a concrete matrix.

[0049] FIG. 2) shows a first example of a contoured, fiber-reinforced plastic profile according to the invention (1) shown in a schematic top view (FIG. 2a)) and side view (FIG. 2b)). For the diagram of the side view, the plastic profile (1) is rotated around the central axis (M) by 90 as seen from above. The contoured, fiber-reinforced plastic profile (1) is composed of a unidirectional-fiber-reinforced plastic base element (8) to which short-fiber-reinforced profiling in the form of a rib structure (1.1) is at least partially attached. Not only is the area of the profiling (1.1) provided with a short- and/or long-fiber-reinforced matrix (9.1), but during application of the short and/or long fibers (9) and the second plastic matrix, the plastic base element (8) is completely covered, so that the short- and/or long-fiber-reinforced matrix (9.1) completely encloses the plastic base element (8), as shown in FIG. 2c). The rib structure (1.1) is not configured circumferentially around the plastic base element (8), but is limited in each case to a maximum of 170 relative to the circumference, wherein the rib structure (1.1) is continuously formed from the base material (9.1) up to a pre-defined height (h). The rib structure (1.1) can preferably be configured at an angle to the central axis (M) with a specified width (b) and with a repeating arrangement at a distance (a). The height (h), width (b), and/or distance (a) of the rib structure (1.1) can be individually set as needed by using a short and/or long fiber (9) for reinforcing the profiling (1.1), and in particular can be arranged in a manner appropriate for the load path.

[0050] FIG. 3) shows a second example of a contoured, fiber-reinforced plastic profile according to the invention (1) in a schematic top view (FIG. 3a)) and side view (FIG. 3b)). In contrast to FIG. 2), the profiling has a rib structure (10.11, 10.12) at least partially reinforced with short and/or long fibers (10.1) having a repeating pattern which, however, is oriented (10.11, a) and (10.12, 13) at different angles to the central axis (M). For example, the angles are =45 and =65. During application of the short and/or long fiber (9) and the second plastic matrix, the plastic base element (8) is covered only locally with short and/or long fibers in the area of the profiling to be produced (10.1), so that the short- and/or long-fiber-reinforced matrix (9.1) is provided only in the area of the profiling (10.1), as shown in FIG. 2c).

[0051] Furthermore, a core material (17) can be provided inside the unidirectional-fiber-reinforced plastic base element (8), in particular in order to allow the diameter (d) of the contoured, fiber-reinforced plastic profile (1) to be increased with simultaneously reduced fiber and matrix material usage.

[0052] FIG. 4) shows a third example of a contoured, fiber-reinforced plastic profile according to the invention (1) in a schematic top view (FIG. 4a)) and side view (FIG. 4b)). The at least partially short- and/or long-fiber-reinforced profiling (1.1) is composed of a first plateau-like structure (1.11) that defines a first partial plane (E.sub.1) and a one-piece rib-shaped structure (1.12) arranged thereon with two ribs arranged parallel to each other and at an angle to the central axis (M) that define a second partial plane (E.sub.2). Not only is the area of the profiling (1.1) provided with a short- and/or long-fiber-reinforced matrix (9.1), but in the process of applying the short and/or long fiber (9) and the second plastic matrix, the plastic base element (8) is completely covered so that the short- and/or long-fiber-reinforced matrix (9.1) fully encloses the plastic base element (8), as shown in FIG. 4c).

[0053] FIG. 5) shows a fourth example of a contoured, fiber-reinforced plastic profile according to the invention (1) in a schematic top view (FIG. 5a)) and side view (FIG. 5b)). In contrast to FIG. 2), the profiling is at least partially reinforced with short and/or long fibers (1.1), with an arrangement that varies in the longitudinal direction of a hemispherical structure (1.11) and a lens structure (1.12). Not only is the area of the profiling (1.1) provided with a short- and/or long-fiber-reinforced matrix (9.1), but the short- and/or long-fiber-reinforced matrix (9.1) completely encloses the plastic base element (8), as shown in FIG. 5c).

[0054] FIG. 6) shows an example of connection of two plastic profiles (1) using the example of the embodiment of FIG. 4). In the process of producing the plastic profiles, one can produce not only a profiling that is appropriate for the load, but also connection areas (18) that are molded onto the plastic profile strand during continuous production in a continuously recurring manner depending on the length of the plastic profile to be produced, wherein the plastic profile strand is cut off in particular in the middle of the connection areas produced in order to provide a plastic profile that has connection areas (18) at both ends. The geometry of the connection areas (18) can be individually adjusted, and they are preferably configured such that at least two plastic profiles can be connected to each other at their ends via a connecting element (19), preferably in a positive locking and/or non-positive locking manner, in particular via their respective connection areas (18). The connection areas (18) in FIG. 6) show axial grooves, wherein other forms are also conceivable. The production of connection areas (18) is not limited to the example (1) according to FIG. 4), but is applicable to all plastic profiles according to the invention (1, 1, 1, 1). The plastic profile (1, 1, 1, 1) can have a connection area (18) at one end, and preferably at both of its ends.

[0055] The invention is not limited to the description or the examples, with combinations of the examples also being possible.

[0056] Rather, the contoured, fiber-reinforced plastic profile can be configured as a solid or hollow profile and/or as a hybrid profile composed of at least two different materials. An (identical) matrix can also be used as the first and second plastic matrix.

LIST OF REFERENCE NOS.

[0057] 1, 1, 1, 1 Contoured, fiber-reinforced plastic profile [0058] 2 First reinforcing fiber [0059] 2.1 Rollers [0060] 2.2 Fiber rack, unwinding unit [0061] 3 Unit for combining the first reinforcing fibers [0062] 3.1 Fiber guide [0063] 4 Fiber bundle [0064] 5 Unit for impregnating the fiber bundle [0065] 6 Unit for providing the first plastic matrix [0066] 6.1, 6.2 Matrix system [0067] 7 Heated shaping unit [0068] 8 Fiber-reinforced plastic base element [0069] 9 Second reinforcing fiber, short and/or long fiber [0070] 9.1 Short- and/or long-fiber-reinforced matrix [0071] 10 Unit for providing the second plastic matrix [0072] 10.1, 10.2 Matrix system [0073] 11 Unit for applying the second reinforcing fibers/second plastic matrix [0074] 12 Electrostatic charging unit/stripping unit [0075] 13 Profiling/shaping unit [0076] 14 Contoured, fiber-reinforced plastic strand [0077] 15 Draw-off/drive unit [0078] 16 Cutting unit [0079] 17 Core material [0080] 18 Connection area [0081] 19 Connecting element [0082] a Distance between rib structures [0083] A Central axis [0084] b Width of rib structure [0085] d Diameter [0086] E.sub.1, E.sub.2 Planes [0087] h Height of rib structure [0088] , Angle