Profile Part and Method for the Production of a Profile Part

Abstract

A profile part is disclosed. The profile part has an inner profile formed as an extrusion profile and has at least one reinforcing layer made from fiber-reinforced plastic which is applied to the inner profile. The inner profile is formed from at least two layers.

Claims

1.-10. (canceled)

11. A profile part, comprising: an inner profile formed as an extrusion profile; and a reinforcing layer made from fiber-reinforced plastic, wherein the reinforcing layer is applied to the inner profile; wherein the inner profile is formed from at least two layers.

12. The profile part according to claim 11, wherein the reinforcing layer is applied by applying an endless fiber material to the inner profile.

13. The profile part according to claim 11, wherein the profile part is produced by internal high-pressure forming of the inner profile with the reinforcing layer.

14. The profile part according to claim 11, wherein the inner profile has an outer layer with a same matrix material as the reinforcing layer.

15. The profile part according to claim 11, wherein the inner profile has an inner layer which is a support layer.

16. The profile part according to claim 11, wherein the inner profile has an intermediate layer which is a support layer.

17. The profile part according to claim 11, wherein the inner profile has an inner layer which has a gas-impermeable plastic.

18. The profile part according to claim 11, wherein the inner profile has an inner layer which is made from a gas-impermeable plastic.

19. A method for producing a profile part, comprising the steps of: extruding an inner profile having at least two layers; applying a reinforcing layer made from fiber-reinforced plastic to the inner profile; and consolidating the reinforcing layer on the inner profile.

20. The method according to claim 19, wherein the reinforcing layer is applied to the inner profile by applying an endless fiber material to the inner profile.

21. The method according to claim 19, wherein the reinforcing layer is applied to the inner profile immediately after the extruding.

22. The method according to claim 19, wherein the profile part is formed with internal high-pressure and/or is bent and/or is extrusion coated with a plastic at least in regions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] FIG. 1 is a schematic cross-sectional view of an exemplary embodiment of a profile part, and

[0051] FIG. 2 is a schematic depiction of a preferred embodiment of a production method for the production of the profile part.

DETAILED DESCRIPTION OF THE DRAWINGS

[0052] FIG. 1 shows a schematic cross-sectional view of an exemplary embodiment of a profile part 1. The cross-sectional plane is thus a plane to which a longitudinal axis L of the profile part 1 is perpendicular. The profile part 1 has an inner profile 3 which is produced as an extrusion profile. In this case, an extrusion direction of the inner profile preferably extends along the longitudinal axis L. The inner profile 3 and also the entire profile part 1 is preferably produced as a continuous profile, wherein it is preferably separated or cut into individual pieces at the end of the production process.

[0053] The profile part 1 also has a reinforcing layer 5 which consists of fiber-reinforced plastic. The reinforcing layer 5 is applied to the inner profile 3.

[0054] The inner profile 3 has at least two layers, in the embodiment shown here exactly three layers. In this case, these are an outer layer 7, an intermediate layer 9 and an inner layer 11.

[0055] The reinforcing layer 5 has reinforcing fibers 13 which are formed as long fibers. In particular, the reinforcing layer 5 is preferably applied to the inner profile 3 by hybrid fiber rovings comprising reinforcing fibers and a matrix material being applied, in particular braided, to the inner profile 3. For the reinforcing fibers 13, plastic fibers, glass fibers, metal fibers, ceramic fibers, aramid fibers or basalt fibers are possible in particular. It is also possible for the reinforcing layer 5 to have a plurality of different fibers made from different fiber materials. A matrix material is provided either in the form of matrix fibers and/or in the form of a coating of the reinforcing fibers 13 in the hybrid fiber rovings of the continuous fiber material. Suitable matrix materials are, in particular, polyamide or polyphthalamide. PA 6 is preferably used as a matrix material for the reinforcing layer 13.

[0056] The outer layer 7 preferably has a matrix material for a fiber-reinforced plastic, particularly preferably the same material which is comprised as a matrix material by the reinforcing layer 13. It is possible that the outer layer 7 is made from this material. Furthermore, it is possible for the outer layer 7 to have a fiber-reinforced plastic or to consist of a fiber-reinforced plastic, wherein short fibers are used as reinforcing fibers in particular. A thermoplastic, preferably polyamide or polyphthalamide, in particular PA 6, is possible as a material for the outer layer 7.

[0057] The intermediate layer 9 preferably has more rigid and/or stronger material properties than the outer layer 7. It is preferably formed as a support layer which serves in particular to absorb and support mechanical forces introduced into the profile part 1, either by forces caused by internal pressure during internal high-pressure forming, pressure forces acting from the outside during extrusion coating of the profile part 1 with plastic, bending forces during the forming of the profile part 1, or forces introduced into the profile part 1 when this is used. The intermediate layer 9 preferably has or consists of a thermoplastic. In particular, the intermediate layer 9 preferably has a material or consists of a material which is selected from a group consisting of polyamide 6.6, polyphthalamide, liquid crystal polymer (LCP), polyetherimide (PEI), polyphenylene sulphide (PPS), polysulfone (PSU) PA 12, polyimide, polyetheretherketone, polyoxymethylene and radiation-crosslinked polyamide. It is possible that the material of the intermediate layer 9 is foamed.

[0058] The inner layer 11 preferably has a gas-impermeable plastic or consists of a gas-impermeable plastic. In this way, the profile part can be formed as a whole simply and securely by internal high-pressure forming without fear of the profile part 1 bursting or cracking. The inner layer 11 preferably has or consists of a thermoplastic. Preferably, the inner layer 11 has or consists of a material which is selected from a group consisting of polyamide 6.6, polyphthalamide, liquid crystal polymer (LCP), polyetherimide (PEI), polyphenylene sulphide (PPS), polysulfone (PSU), PA 12, polyimide, polyetheretherketone, polyoxymethylene and radiation-crosslinked polyamide. It is possible that the material of the inner layer 11 is foamed.

[0059] The material of the intermediate layer 9 and/or of the inner layer 11 can comprise fiber-reinforced plastic or consist of fiber-reinforced plastic. In this case, short fibers are used in particular as reinforcing fibers.

[0060] Therefore, only the reinforcing layer 5 preferably has long fibers which are preferably braided. On the other hand, the outer layer 7, the intermediate layer 9 and the inner layer 11 have short fibers as reinforcing fibers when they have fiber-reinforced plastic.

[0061] When the reinforcing layer 5 is consolidated, it is preferably connected integrally to the outer layer 7, wherein a layer boundary 15 passes between the two layers 5, 7 and particularly preferably is no longer present. It is shown schematically in FIG. 1. In particular, however, if the material of the outer layer 7 is different from the matrix material of the reinforcing layer 5, the layer boundary 15 can also remain more or less defined during consolidation of the reinforcing layer 5.

[0062] FIG. 2 shows a schematic depiction of an embodiment of a method for the production of the profile part 1. A braided pultrusion device 17 is used for producing the profile part 1. This has a multi-component extruder 19, by means of which the inner profile 3 is continuously produced as a continuous profile. As seen along the extrusion direction, a braiding unit 21 is arranged downstream of the multi-component extruder 19, through which the inner profile 3 is guided as a braided core. On this braided core, therefore on the inner profile 3, the continuous fiber material for the reinforcing layer 5 is braided by the braiding unit 21. Several braiding wheels 25 are provided for this purpose. A pultrusion unit 27 is arranged downstream of the braiding unit 21, as seen in the feed direction of the inner profile 3. In this, the reinforcing layer 5 is consolidated on the inner profile 3. In an inherently known manner, the pultrusion unit 27 also serves to post-form the profile part 1, by the profile part 1 preferably being pressed through an input matrix of the pultrusion unit. Bending of the profile part 1 in the pultrusion unit 27 is also possible.

[0063] The pultrusion unit 27 also has a withdrawing device 29 for withdrawing the profile part 1, which is initially formed as a continuous profile. The multi-component extruder 19 also preferably has a separate withdrawing device 31, wherein in this case the withdrawal forces can be distributed more homogeneously over the entire length of the resulting continuous profile.

[0064] As seen in the feed direction of the continuous profile, a separating device 33 is preferably arranged behind the withdrawal device 29, by means of which the continuous profile can be separated or cut into separate profile parts 1.

[0065] FIG. 2 shows that the profile part 1 is preferably produced in an integrated process, wherein the application of the reinforcing layer 5 in the braiding unit 21 takes place immediately after the extrusion of the inner profile 3, such that the reinforcing layer 5 is applied directly to the extruded continuous inner profile 3. The pultrusion and consolidation of the reinforcing layer 5 takes place directly afterwards, as well as the separation into individual profile parts 1.

[0066] The resulting profile parts 1 are preferably subjected to an internal high-pressure forming method in order to give them a desired shape. Alternatively or additionally, it is possible for the profiled parts 1 to be extrusion coated at least in regions with a plastic, in particular a fiber-reinforced plastic and very particularly preferably a short-fiber-reinforced plastic. In this case, connecting elements are particularly preferably injection molded onto the profile parts 1, which ultimately serve for the connection to adjacent components of an assembly, for which the profile parts 1 are used. In this case, this is particularly preferably panelling parts of a vehicle body, in particular of a motor vehicle, preferably of a lorry.

[0067] Through the specific selection of the plastics used, the profile part 1 can in particular also be formed to be chemical-resistant. In addition, the plastics used can preferably be used in a wide temperature range, in particular from −40° C. to 90° C. In this way, increased performance values for the profile part 1 are possible, with simultaneous weight and cost savings due to the multi-material mix used. In this case, it is easily possible to introduce materials with liquid or gas-impermeable, chemical-resistant and friction-reducing properties through the selection of the different layers.

[0068] By virtue of the fact that the inner profile 3, which is used as a braided core, moves with the continuous fibers to be applied in the braiding unit 21, the withdrawal forces, which the withdrawal device 29 must apply, also decrease. There is also a significantly lower probability of fiber tears than in the event of application to a fixed braided core.

[0069] Overall, an ideally torsion and bend-resistant, closed hollow profile is able to be produced as a profile part 1 by means of the method. The method represents a highly integrated production process which is suitable for series production. The profile part 1 has a recyclable material concept, wherein the profile part 1 can be used in particular as a technically usable, reinforced plastic granulate in the course of recycling. The integration of all production processes for the profile part 1 results in a considerable cost and energy savings. The performance capabilities of the profile part 1 can be increased by integrating different materials and, in particular, by the multi-layered inner profile 3, wherein the profile part 1 can be tailor-made to the requirements in particular. In particular, this can be provided with increased strength and rigidity. Gas-impermeable properties are possible, in addition the profile part 1 can be resistant to media and temperature and can have particularly favorable sliding properties. Finally, it is also possible to improve the NVH behavior (noise, vibration, harshness) of the profile part 1.