DE102014221387B4 - Process for producing a foam core in a hollow profile and hollow profile with foam core - Google Patents

Process for producing a foam core in a hollow profile and hollow profile with foam core Download PDF

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DE102014221387B4
DE102014221387B4 DE102014221387.8A DE102014221387A DE102014221387B4 DE 102014221387 B4 DE102014221387 B4 DE 102014221387B4 DE 102014221387 A DE102014221387 A DE 102014221387A DE 102014221387 B4 DE102014221387 B4 DE 102014221387B4
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hollow profile
profile
foam core
cross
foam
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DE102014221387A1 (en
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Maik Hammer
Matthias Pernicka
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Bayerische Motoren Werke AG
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Bayerische Motoren Werke AG
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/02—Layer formed of wires, e.g. mesh
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B29C44/0446—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities by increasing the density locally by compressing part of the foam while still in the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/18—Filling preformed cavities
    • B29C44/188—Sealing off parts of the cavities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/04—Inorganic
    • B32B2266/045—Metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars

Abstract

Verfahren zum Herstellen eines Schaumstoffkerns (2) in einem im Querschnitt geschlossenen Hohlprofil (1), bei dem von einem der Profilenden aus eine fließfähige, treibmittelversetzte Füllmasse eingefüllt wird, welche im Hohlprofil aufschäumt und sich zu einem integralen Schaumstoffkern verfestigt, dadurch gekennzeichnet, dass an mindestens einer vorgegebenen Stelle im Hohlprofil ein Bereich (2a, b) erhöhter Schaumdichte (D) dadurch erzeugt wird, dass vor dem Einfüllen der Füllmasse in Befüllrichtung stromabwärts des dichteren Schaumkernbereichs und an diesen angrenzend eine Querschnittsverengung (3) im Hohlprofil vorgesehen wird.Method for producing a foam core (2) in a hollow profile (1) with a closed cross-section, in which a flowable filling compound containing a blowing agent is filled in from one of the profile ends, which foams up in the hollow profile and solidifies to form an integral foam core, characterized in that an area (2a, b) of increased foam density (D) is produced at at least one predetermined location in the hollow profile by providing a cross-sectional constriction (3) in the hollow profile before the filling compound is filled in, downstream of the denser foam core area in the filling direction and adjacent to it.

Description

Die Erfindung bezieht sich auf ein Verfahren zur Herstellung eines Schaumstoffkerns für ein im Querschnitt geschlossenes Hohlprofil, bei dem das Hohlprofil von einem der Profilenden aus mit einer fließfähigen Füllmasse mit einem durchgehend gleichbleibenden Treibmittelgehalt befüllt wird, welche im Hohlprofil aufschäumt und sich zu einem integralen Schaumstoffkern verfestigt, nach dem Oberbegriff des Patentanspruchs 1, sowie auf ein so hergestelltes Hohlprofil nach den gattungsgemäßen Merkmalen des Patentanspruchs 5.The invention relates to a method for producing a foam core for a hollow profile with a closed cross-section, in which the hollow profile is filled from one of the profile ends with a flowable filling compound with a consistently constant blowing agent content, which foams up in the hollow profile and solidifies to form an integral foam core, according to the preamble of patent claim 1, and to a hollow profile produced in this way according to the generic features of patent claim 5.

Es ist bekannt, im Querschnitt geschlossene Hohlprofile, z. B. in Form von Rahmenteilen von Kraftfahrzeugen, durch einen spezifisch leichten Schaumstoffkern zu verstärken. Zu diesem Zweck wird das Hohlprofil mit einer fließfähigen, mit einem Treibmittel versetzten Füllmasse auf Metall- oder Kunststoffbasis befüllt, welche im Profilinneren aufschäumt und sich zu einem integralen Schaumstoffkern verfestigt. Um die Lastfestigkeit derartiger Hohlprofile an die örtlichen Belastungen anzupassen, ist es ferner bekannt, die Hohlprofile in einzelne Kammern zu unterteilen und diese jeweils mit Integralschäumen unterschiedlicher Schaumdichte und dementsprechend unterschiedlicher Verstärkungswirkung auszufüllen, was jedoch mit einem deutlich höheren Herstellungsaufwand verbunden ist, als wenn das Hohlprofil in einem einzigen Befüllvorgang von einem der Profilenden aus durchgehend über die gesamte Profillänge ausgeschäumt wird.It is known to reinforce hollow profiles with a closed cross-section, e.g. in the form of frame parts of motor vehicles, with a specifically light foam core. For this purpose, the hollow profile is filled with a flowable metal or plastic-based filling compound mixed with a blowing agent, which foams up inside the profile and solidifies to form an integral foam core. In order to adapt the load-bearing capacity of such hollow profiles to the local loads, it is also known to divide the hollow profiles into individual chambers and fill each of these with integral foams of different foam densities and correspondingly different reinforcing effects, which, however, involves significantly higher manufacturing costs than if the hollow profile were foamed in a single filling process from one of the profile ends over the entire length of the profile.

Das Dokument DE 25 48 272 A1 betrifft ein Verfahren zur Herstellung einer wärmeisolierenden geschlossenen Anordnung. Um ein Verfahren zur Herstellung einer wärmeisolierenden, geschlossenen Anordnung zu schaffen, welches in einfacher Weise im Freien auszuführen ist und zu einer Anordnung mit ausgezeichneten Wärmeisolationseigenschaften führt, wird in dem Dokument DE 25 48 272 A1 vorgeschlagen, eine zusammengesetzte Membran herzustellen, die eine innere Membran aus einem gasdurchlässigen Gewebe hat, welche auf einem bestimmten Abstand von der Innenseite einer äußeren Membran angeordnet wird, welche aus einem gasundurchlässigen Material hergestellt wird, wobei die beiden Membranen durch Abstandsstücke auf Abstand voneinander gehalten werden, wobei dann die Ränder der zusammengesetzten Membran an einem wärmeisolierenden Bodenelement befestigt werden, wobei dann ein Druck in den von der zusammengesetzten Membran und dem wärmeisolierenden Bodenelement umgebenen Raum eingeleitet wird, um dadurch das zusammengesetzte Membranelement aufzublasen, so dass es von selbst angehoben wird, und wobei eine Schaumfüllung in den Zwischenraum zwischen der inneren Membran und der äußeren Membran eingebracht wird, die man aufschäumen und aushärten lässt.The document DE 25 48 272 A1 relates to a method for producing a heat-insulating closed arrangement. In order to create a method for producing a heat-insulating closed arrangement which can be carried out in a simple manner outdoors and results in an arrangement with excellent heat insulation properties, the document DE 25 48 272 A1 proposed to produce a composite membrane having an inner membrane made of a gas-permeable fabric which is arranged at a certain distance from the inside of an outer membrane made of a gas-impermeable material, the two membranes being kept at a distance from each other by spacers, the edges of the composite membrane then being attached to a heat-insulating floor element, pressure then being introduced into the space surrounded by the composite membrane and the heat-insulating floor element to thereby inflate the composite membrane element so that it is raised by itself, and a foam filling being introduced into the space between the inner membrane and the outer membrane, which is allowed to foam and harden.

Aufgabe der Erfindung ist es, ein Verfahren und ein Hohlprofil der eingangs genannten Art so auszubilden, dass das Profilinnere auf fertigungstechnisch einfache Weise einen Schaumstoffkern mit einer in Profillängsrichtung den örtlichen Belastungen des Hohlprofils entsprechend unterschiedlichen Verstärkungswirkung enthält.The object of the invention is to design a method and a hollow profile of the type mentioned at the outset in such a way that the profile interior contains, in a technically simple manner, a foam core with a reinforcing effect which varies in the longitudinal direction of the profile according to the local loads on the hollow profile.

Diese Aufgabe wird erfindungsgemäß durch das im Patentanspruch 1 gekennzeichnete Verfahren bzw. das im Patentanspruch 5 gekennzeichnete Hohlprofil gelöst. Vorteilhafte Ausgestaltungen der Erfindung sind in den Unteransprüchen beschrieben.This object is achieved according to the invention by the method characterized in patent claim 1 or the hollow profile characterized in patent claim 5. Advantageous embodiments of the invention are described in the subclaims.

Die Erfindung beruht auf der Erkenntnis, dass sich die Schaumbildung einer das Hohlprofil durchströmenden, treibmittelversetzten Füllmasse an einer Querschnittsverengung des Hohlprofils derart verändert, dass stromaufwärts der Querschnittverengung und an diese angrenzend eine Zone erhöhter Schaumdichte entsteht, was erfindungsgemäß dazu ausgenutzt wird, die Verstärkungswirkung des Schaumstoffkerns auf fertigungstechnisch einfache Weise an die örtlichen Belastungen des Hohlprofils dadurch anzupassen, dass im Hohlprofil zuvor eine Querschnittsverengung in unmittelbarer Nähe zum stärker belasteten Profilbereich positioniert und dann beim Einfüllen der treibmittelversetzten Füllmasse die Strömungsrichtung so gewählt wird, dass der stärker belastete Profilbereich auf der Anströmseite der Querschnittsverengung liegt. The invention is based on the finding that the foam formation of a blowing agent-added filling compound flowing through the hollow profile changes at a cross-sectional constriction of the hollow profile in such a way that a zone of increased foam density is created upstream of the cross-sectional constriction and adjacent to it, which is exploited according to the invention to adapt the reinforcing effect of the foam core to the local loads of the hollow profile in a manufacturing-technically simple manner by previously positioning a cross-sectional constriction in the hollow profile in the immediate vicinity of the more heavily loaded profile area and then, when filling in the blowing agent-added filling compound, the flow direction is selected so that the more heavily loaded profile area is on the upstream side of the cross-sectional constriction.

Nach Anspruch 2 werden auf die erfindungsgemäße Weise vorzugsweise mehrere Schaumstoffbereiche erhöhter Schaumdichte im Schaumstoffkern ausgebildet, um so auch Hohlprofile mit einer in Profillängsrichtung mehrmals erhöhten Lastverteilung durch die Schaumstofffüllung belastungsgerecht zu verstärken.According to claim 2, preferably several foam regions of increased foam density are formed in the foam core in the manner according to the invention in order to reinforce hollow profiles with a load distribution increased several times in the longitudinal direction of the profile by the foam filling in a load-appropriate manner.

In besonders bevorzugter Ausgestaltung werden die Befüllparameter und insbesondere die Zusammensetzung der Füllmasse nach Anspruch 3 so gewählt, dass diese am stromabwärtigen Profilende einen zumindest teilweise verfestigten Zustand erreicht. Weil der erfindungsgemäß erzielte Verdichtungseffekt strömungsabhängig ist, wird hierdurch sichergestellt, dass sämtliche Querschnittsverengungen beim Befüllvorgang von der Füllmasse durchströmt werden, und zugleich erreicht, dass sich die aufschäumende Füllmasse ausgehend vom stromabwärtigen Profilende auf dem Weg über die Querschnittsverengung(en) zunehmend verfestigt.In a particularly preferred embodiment, the filling parameters and in particular the composition of the filling compound according to claim 3 are selected such that it reaches an at least partially solidified state at the downstream profile end. Because the compaction effect achieved according to the invention is flow-dependent, this ensures that the filling compound flows through all cross-sectional constrictions during the filling process, and at the same time ensures that the foaming filling compound increasingly solidifies starting from the downstream profile end on the way over the cross-sectional constriction(s).

In vielen Anwendungsfällen empfiehlt es sich, wie nach Anspruch 4 bevorzugt, für den Schaumstoffkern einen Metallschaum vorzusehen.In many applications, it is recommended, as preferred according to claim 4, to provide a metal foam for the foam core.

Nach einer herstellungsmäßig bevorzugten Ausführungsform wird die Querschnittsverengung des Hohlprofils gemäß Anspruch 6 nach Art einer Strömungsblende ausgebildet, und in diesem Fall lässt sich das Ausmaß der örtlich erzielten Dichtezunahme bauseitig auf einfache Weise in Abhängigkeit von der jeweils gewählten Querschnittsgröße der Blendenöffnung vorgeben.According to a preferred embodiment in terms of production, the cross-sectional constriction of the hollow profile according to claim 6 is designed in the manner of a flow orifice, and in this case the extent of the locally achieved density increase can be specified on site in a simple manner depending on the respectively selected cross-sectional size of the orifice opening.

Die Erfindung wird nunmehr an Hand eines Ausführungsbeispiels in Verbindung mit den Zeichnungen näher erläutert. Es zeigen in stark schematisierter Darstellung:

  • 1 mehrere schaumkernverstärkte Hohlprofilträger in jeweils unterschiedlichen Einbauorten und -funktionen eines Kraftfahrzeugs: und
  • 2a, b eines der in 1 dargestellten Hohlprofile ausschnittweise im Längsschnitt zusammen mit dem zugehörigen, qualitativen Dichteverlauf des Schaumstoffkerns (a) und im Querschnitt (b).
The invention will now be explained in more detail using an embodiment in conjunction with the drawings. They show in a highly schematic representation:
  • 1 several foam core reinforced hollow profile beams in different installation locations and functions of a motor vehicle: and
  • 2a , b one of the 1 shown hollow profiles in longitudinal section together with the corresponding qualitative density curve of the foam core (a) and in cross section (b).

Die in 1 ausschnittsweise in perspektivischer Darstellung gezeigte Fahrzeugkarosserie enthält mehrere, aus Gewichtsgründen jeweils durch einen spezifisch leichten Schaumstoffkern im Profilinneren verstärkte, im Querschnitt geschlossene Hohlprofile 1 in Form von Schwellern 1.1, Motor-Längsträgern 1.2 und eines stirnwandseitigen Querträgers 1.3. In den stärker belasteten Profilbereichen besitzt der Schaumstoffkern 2 (2a) eine erhöhte Schaumdichte D und eine demensprechend erhöhte Verstärkungswirkung, also etwa den in 2a gezeigten Dichteverlauf D. Zu diesem Zweck werden im Hohlprofil 1 vor dem Ausschäumen angrenzend an die Schaumkernbereiche 2a, b, die eine erhöhte Schaumdichte D aufweisen sollen, Querschnittsverengungen 3 positioniert, welche bei dem gezeigten Ausführungsbeispiel nach Art einer Strömungsblende gestaltet sind und beim Verschweißen des aus zwei Halbschalen 4.1, 4.2 zusammengefügten Hohlprofils 1 (2b) mit den Halbschalen 4 mitverschweißt werden. Beim Ausschäumen des Hohlprofils 1 wird die Einfüllrichtung E so gewählt, dass die Schaumkernbereiche 2a, b erhöhter Schaumdichte D strömungsaufwärts der Querschnittsverengungen 3 zu liegen kommen. Dabei wird die treibmittelversetzte Füllmasse derart voreingestellt, dass sie an dem dem einfüllseitigen gegenüberliegenden Profilende einen zumindest teilweise verfestigten Zustand erreicht. Durch entsprechende Einstellung der Prozessparameter und insbesondere der Größe der Blendenöffnung 5 lässt sich das Ausmaß der örtlichen Dichteerhöhung vorherbestimmen und so eine hochgradig belastungsgerechte Dichteverteilung des Schaumstoffkerns 2 erreichen, also z. B. der in 2a gezeigte Dichteverlauf D mit einer von Strömungsblende 3 zu Strömungsblende 3 allmählich geringeren Dichteerhöhung.In the 1 The vehicle body shown in a perspective view contains several hollow profiles 1 with a closed cross-section, each reinforced by a specifically lightweight foam core in the interior of the profile for weight reasons, in the form of sills 1.1, engine longitudinal members 1.2 and a front wall cross member 1.3. In the profile areas subject to greater stress, the foam core 2 ( 2a) an increased foam density D and a correspondingly increased reinforcing effect, i.e. approximately the 2a shown density curve D. For this purpose, cross-sectional constrictions 3 are positioned in the hollow profile 1 before foaming adjacent to the foam core areas 2a, b, which are to have an increased foam density D, which in the embodiment shown are designed in the manner of a flow baffle and when welding the hollow profile 1 ( 2 B) welded to the half shells 4. When foaming the hollow profile 1, the filling direction E is selected so that the foam core areas 2a, b of increased foam density D are located upstream of the cross-sectional constrictions 3. The filling compound with the blowing agent is preset in such a way that it reaches an at least partially solidified state at the profile end opposite the filling side. By setting the process parameters accordingly and in particular the size of the aperture 5, the extent of the local density increase can be predetermined and thus a density distribution of the foam core 2 that is highly load-appropriate can be achieved, i.e. for example the density in 2a shown density curve D with a gradually decreasing density increase from flow orifice 3 to flow orifice 3.

Claims (7)

Verfahren zum Herstellen eines Schaumstoffkerns (2) in einem im Querschnitt geschlossenen Hohlprofil (1), bei dem von einem der Profilenden aus eine fließfähige, treibmittelversetzte Füllmasse eingefüllt wird, welche im Hohlprofil aufschäumt und sich zu einem integralen Schaumstoffkern verfestigt, dadurch gekennzeichnet, dass an mindestens einer vorgegebenen Stelle im Hohlprofil ein Bereich (2a, b) erhöhter Schaumdichte (D) dadurch erzeugt wird, dass vor dem Einfüllen der Füllmasse in Befüllrichtung stromabwärts des dichteren Schaumkernbereichs und an diesen angrenzend eine Querschnittsverengung (3) im Hohlprofil vorgesehen wird.Method for producing a foam core (2) in a hollow profile (1) with a closed cross-section, in which a flowable filling compound containing a blowing agent is filled in from one of the profile ends, which foams up in the hollow profile and solidifies to form an integral foam core, characterized in that an area (2a, b) of increased foam density (D) is produced at at least one predetermined location in the hollow profile by providing a cross-sectional constriction (3) in the hollow profile before the filling compound is filled in, downstream of the denser foam core area in the filling direction and adjacent to it. Verfahren nach Anspruch 1, dadurch gekennzeichnet dass in Profillängsrichtung hintereinanderliegend mehrere Schaumkernbereiche (2a und 2b) erhöhter Schaumdichte an jeweils entsprechend positionierten Querschnittsverengungen (3) erzeugt werden.Procedure according to Claim 1 , characterized in that several foam core regions (2a and 2b) of increased foam density are produced one behind the other in the longitudinal direction of the profile at correspondingly positioned cross-sectional constrictions (3). Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet dass die Füllmasse unter Berücksichtigung der Befüllparameter so gewählt wird, dass diese am stromabwärtigen Profilende einen zumindest teilweise verfestigten Zustand erreicht.Method according to one of the preceding claims, characterized in that the filling mass is selected taking into account the filling parameters such that it reaches an at least partially solidified state at the downstream profile end. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet dass als Schaumstoffkern (2) ein mit einer bereichsweise erhöhten Schaumdichte aufschäumender Metallschaum vorgesehen wird.Method according to one of the preceding claims, characterized in that a metal foam which foams up with a partially increased foam density is provided as the foam core (2). Hohlprofil (1) mit einem im Profilinneren angeordneten Schaumstoffkern (2) aus einer am einem Profilende eingefüllten, mit einem Treibmittel versetzten und im Hohlprofil aufschäumenden Füllmasse, dadurch gekennzeichnet, dass das Hohlprofil mindestens eine Querschnittsverengung (3) und an diese angrenzend auf der dem einfüllseitigen Profilende zugewandten Seite der Querschnittsverengung einen Schaumkernbereich (2a, b) erhöhter Schaumdichte aufweist.Hollow profile (1) with a foam core (2) arranged in the interior of the profile and made of a filling compound filled at one end of the profile, mixed with a blowing agent and foaming in the hollow profile, characterized in that the hollow profile has at least one cross-sectional constriction (3) and, adjacent to this, on the side of the cross-sectional constriction facing the filling-side profile end, a foam core region (2a, b) of increased foam density. Hohlprofil nach Anspruch 5, dadurch gekennzeichnet dass als Querschnittsverengung (3) ein nach Art einer Strömungsblende ausgebildetes Einbauteil im Profilinneren angeordnet ist.Hollow profile according to Claim 5 , characterized in that an installation part designed in the manner of a flow orifice is arranged in the profile interior as a cross-sectional constriction (3). Hohlprofil nach Anspruch 6, dadurch gekennzeichnet dass das Einbauteil eine gegensinnig zur örtlichen Dichteerhöhung bemessene Blendenöffnung (5) besitzt.Hollow profile according to Claim 6 , characterized in that the built-in part has an aperture (5) dimensioned in the opposite direction to the local density increase.
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DE2548272A1 (en) 1974-10-29 1976-05-06 Showa Denko Kk THERMAL-INSULATING, CLOSED ARRANGEMENT AND METHOD OF MANUFACTURING IT
DE3047323A1 (en) 1979-12-31 1981-09-17 Elio 6852 Genestrerio Vassalli "INSULATING ELEMENT FOR THE EXTERNAL WALLS OF A BUILDING AND METHOD AND SYSTEM FOR THE PRODUCTION THEREOF"
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