DE102011085962A1 - Profile shaft for use with internal profile made of fiber composite material in drive shaft of aircraft and motor vehicle, has area that forms profile shell, where profile shell has profiled cross-section with tooth bases and tooth points - Google Patents

Abstract

The profile shaft (2) has an area that forms a profile shell (21), and a layer (211,212) of fiber plastic composite material. The profile shell has a profiled cross-section with tooth bases (213) and tooth points (214). Another area (23) is arranged outside the former area, and is made of fiber plastic composite material. Fibers are provided for filling up recesses or tooth tips. A third area forms a cylindrical shell (25), and is arranged outside the latter area. An independent claim is included for a method for manufacturing a profile shaft.

Description

The invention relates to an internally profiled shaft, made of fiber composite material with load introduction elements and a method for their preparation.

In recent years, waves made of fiber composite material gained in importance. This is due to, compared to conventional shafts made of metallic materials, considerable weight advantages with very good mechanical properties. So find such waves in particular in aircraft, but also in motor vehicles application. Due to the very high natural frequencies of shafts made of FKV, these are particularly suitable for any high-speed machines, such as Turbooder printing presses.

In most cases, the waves are composed of different fiber layers with different fiber orientations, whereby bending stiffness and torsional rigidity can be influenced in a targeted manner. Disadvantageously, the load is introduced into the FKV shaft in the low-strength matrix material and not in the high-strength fibers, which places special demands on the profiled region of the shaft.

Not least, the mass production of FKV waves, which should be done in different demand lengths if possible, due to the complex fiber deposition in different layers in conjunction with the introduction of the internal profiling difficult.

In the DE 196 13 857 a wave of FKV is presented, which has an internal profiling. In this case, the inner fiber layer is axially aligned on the at least one double layer with symmetrically to the axial direction at an angle ± α arranged inclined fibers is applied. Such a shaft can be manufactured in the draw-winding process with high productivity. A disadvantage of this solution is the low strength transverse to the fiber direction of the inner profiling due to the axial fiber orientation.

Object of the present invention is to propose a wave of fiber composite material, which has very good mechanical properties and in particular a very high strength of the profiling. Furthermore, a method for an efficient production of such a profiled shaft in a continuous or quasi-continuous process will be shown.

This object is achieved by a shaft having the features of claim 1. The inventive method for producing the shaft is set forth in claim 12. Preferred embodiments of the invention are set forth in subclaims.

The profile shaft according to the invention with an inner profile is made of fiber composite material and has at least three areas, which are arranged one above the other in the radial direction of the profiled shaft.

The first, inner region of the profiled shaft is a profiled shell, which consists of at least one layer of fiber composite material having a fiber angle of ± 10 ° to ± 80 °, preferably ± 20 ° to ± 70 ° and further preferably ± 30 ° to ± 60 °, based the axial direction of the profiled shaft exists. Particularly preferably, several layers with varying fiber angles are applied. Smaller fiber angles (the angle between the fiber direction and the profile shaft axis) improve the bending stiffness, while larger fiber angles up to about 60 ° improve the torsional stiffness and strength. Another increase of the angle up to max. 90 ° brings an improved absorption of the resulting from the internal profiling with oblique tooth flanks Tangentialspannung (eq. Internal pressure load) and a stiffening of the shaft cross-section, which counteracts the damage pattern, Torsionsbeulen, in the area between the load introduction elements. Thus, by choosing the fiber angle, the mechanical properties of the profile wave can be adjusted specifically. The profile shell has a profiled cross-section with areas defined as tooth tips and tooth tips, wherein the tooth head is a convexity of the inner profile and thus a depression in the outer profile, and the tooth root is accordingly a depression of the inner profile and a bulge of the outer profile. Advantageously, by the profile shell with oblique, i. to the profile shaft axis inclined fiber angle, a high strength of the profile flanks of the internal profiling achieved.

The second area, also referred to as unidirectional area, is located outside the first area, ie directly on the profile shell. It consists of fiber-plastic composite material with fibers arranged in the largely axial direction of the profiled shaft (fiber angle 0 °), which fills the recesses formed in the region of the tooth heads by the profiling of the first region, so that the outer contour of the second region is largely cylindrical. An advantageous method of production envisages producing the final contour identical to the unidirectional fiber layer in an upstream production process, for example by fiber-wet pultrusion. These unidirectionally reinforced strips (also referred to as preconsolidated strips) can then press the fiber layer (s) of the profile shell against the mold core and thus ensure the desired fiber profile in the profile shell.

The third area forms a cylindrical shell, which is arranged directly on the second area. Analogous to the profile shell, the cylindrical shell consists of at least one layer of fiber composite material having a fiber angle of ± 10 ° to ± 80 °, preferably ± 20 ° to ± 70 ° and more preferably ± 30 ° to ± 60 °, based on the axial direction of the profile shaft. Here, too, smaller fiber angles improve the bending stiffness, while larger fiber angles improve the torsional rigidity / strength, absorption of tangential stresses in the load introduction region and stabilization against torsional buckling in the main body of the drive shaft.

Depending on the application profile shell and cylinder shell may consist of a braid, a winding or a mixture of Flechtlagen and winding layers. To be particularly advantageous, it has been found that the profile shell has a braid reinforcement and the cylinder shell has a winding as reinforcement. Other requirements, such as the impact resistance may require deviating configurations.

The profile shaft consists of a fiber-plastic composite, which - depending on the mechanical requirements of the shaft - can vary in terms of the materials used. For high-performance profile shafts, the use of continuous fibers made of carbon is suitable. But other reinforcing materials such as e.g. Glass, aramid or basalt fibers are used for certain requirement profiles.

Thermosetting materials such as e.g. Epoxy, phenolic or polyester resins) or engineering thermoplastics such as polyamide (PA), polyphenylene sulfide (PPS) or polyetheretherketone (PEEK).

However, the above mention of materials is illustrative only and not limiting of the invention.

Furthermore, the unidirectional region preferably consists of unidirectional strips distributed over the circumference of the profile shaft, which are arranged in the depressions / tooth heads of the profile shell. Advantageously, the unidirectional strips provide very good strength and dimensional accuracy of the internal profiling of the profiled shaft by keeping the fiber layers in position even after preforming by means of a suitable profile die / profile die. If the profiling is designed such that the fiber layers of the profiled shell remain well in position after the preforming by the profiled nozzle, a flexible, predominantly unidirectional fiber reinforcement for region 2 can also be used. This reduces the manufacturing effort, since no consolidated strips must be made and increases the mechanical strength, since all areas can be cured / consolidated together.

Particularly preferably, the profile shell consists of two layers of fibers wherein the first, inner layer has a fiber angle to the axial direction of the profile shaft of 50 ° to 70 °, preferably 60 °, and the second, outer layer has a fiber angle to the axial direction of the profile shaft from 40 ° to 50 °, preferably 45 °. Such a profile shell has particularly good mechanical properties, since it brings the mechanical demands for high torsional stiffness / strength, high strength / rigidity in the tangential direction and high strength / stiffness against cross-sectional deformation with favorable machine / manufacturing parameters in line.

For this reason, the cylindrical shell preferably also consists of two layers of fibers, wherein the first, inner layer has a fiber angle to the axial direction of the profile wave of 40 ° to 50 °, preferably 45 °, and the second, outer layer has a fiber angle to the axial direction of the profile shaft of 50 ° to 70 °, preferably 60 °.

In principle, the use of prepregs, preimpregnated fibers and other FKV starting materials is possible to design the inventive structure of the profile shaft.

Further preferably, at least one load introduction element is inserted into the profile shaft, which has a, corresponding to the internal profiling of the profile corrugation external profiling. The load introduction element can be made of different materials, for example, also made of FRP material, particularly preferably with an analogous structure with three areas such as the profile shaft, in which case the profile shell outside and the cylinder shell is arranged inside. The external profiling of the load introduction element also has barbs in the area of the tooth head and / or the tooth root on the outside, which secure the load introduction element by snagging in the profile shaft against slipping out in the axial direction. The barbs can engage in small grooves in the profile shaft or even get caught directly in the material. This attachment of a load introduction element is inexpensive and fast, but not or only partially solvable.

In an alternative embodiment of the axial fixation of the load introduction element has this holes, engage by spring pins mounted on the radial pins in a groove in the interior of the profile shaft. Preferably, the spring elements and the radial pins are arranged on a separate retaining ring, which is inserted into the load introduction element. This alternative is mechanically complicated, but easily solved.

In a further alternative embodiment, the profiled shaft and the load introduction element have outer radial grooves. On the transition from profile shaft to load introduction element, a sleeve, preferably a metal sleeve, is pressed so that it engages in the grooves of the profile shaft and load introduction element, whereby they are positively connected. This alternative is very simple and inexpensive, but only partially solvable.

Alternatively, the attachment of load introduction element in the profile shaft in which the load introduction element has on its circumference a hook element, which is preferably designed as a ring, which is formed by an increase of the tooth tips and / or the tooth feet. A corresponding with the hook element recess in the interior of the profile shaft encloses this, so the profile shaft snaps when inserting the load introduction element on the hook element. In this case, this is preferably formed with a triangular profile, wherein the profiled shaft widens when pushed onto an inclined surface, but after snapping no opposite slope is more present, which could cause a widening of the profile shaft thereby slipping is prevented. Preferably, an additional backup by means of an applied after snapping safety sleeve, which prevents expansion of the profile shaft, which is necessary to release the connection. Further preferably, the profile shaft has in its interior a circumferential spring groove, which facilitates the elastic expansion of the profile shaft for snapping. This connection variant is relatively simple and also solvable.

Furthermore, alternatively, the attachment via a in the profile shaft in the region of the load introduction element introduced from outside and breaking through groove. In this, a ring is introduced which engages over the openings in the profile shaft in a groove in the load introduction element. The ring is preferably an elastically resilient ring or a wet-wound ring, ie a wet winding of reinforcing material.

Not least, alternatively, the attachment can be made via a rotatable bayonet ring located on the load introduction element. The bayonet ring has projecting noses that run in an axial inside groove when inserting the load introduction element in the profile shaft. By rotating the bayonet ring in a subsequent to the axial groove radial groove in the interior of the profile shaft, the load introduction element is secured against axial displacement. As an additional safeguard, locking pins can also prevent the bayonet ring from turning back.

The inventive method for producing a profiled shaft according to the invention comprises the following steps:
In a first step, a split or segmented core tool with a corresponding with the desired inner profile of the profile shaft outer profile is guided by a Faserpreformeinheit or Faserablegeeinheit for the profile shell. This Faserpreformeinheit or Faserablegeeinheit for the profile shell deposits at least one fiber layer (as a winding or braid) on the core. However, depending on the application, it is also conceivable to deposit a plurality of fiber layers, including a mixture of wound and braided layers, whereby the fiber angle can also vary. Preferably, a binder material, preferably as a yarn or as a powder, is introduced during the deposition or directly thereafter. Suitable binder materials are thermosetting and thermoplastic binder materials, preferably a thermoset-based binder is used.

Subsequently, the core tool is guided with the profile shell by a profile die or profile die. This consists of a kind of nozzle - a so-called shaping profile die which has exactly the negative profile of the profile shell. This is preferably heatable or it may be upstream of a heating device. In this step, the binder material is melted and advantageously ensures dimensional accuracy of the profile shell after the profile die. Profile die means that the die / nozzle simulates the cross section of the inner profile of the profile shell.

Subsequently, the second (unidirectional region) FKV material having a fiber direction which largely corresponds to the axial direction of the tread shaft is inserted into the recesses of the tread cup formed by the tooth tips. This is preferably done by means of preconsolidated strips of unidirectionally reinforced FRP material, which is very easy to handle. Alternatively, there is the possibility of a coil unit flaccid, so not preconsolidated reinforcing fibers by means of a downstream template to introduce directly into the wells. An advantage of this alternative is that the flaccid reinforcing fibers used directly from the roll and thus can be fed directly to the process and without upstream production steps. In addition, experience shows that the joint hardening which subsequently takes place can usually be expected to mean a connection of the three profiled shaft areas which can be subjected to higher mechanical loads than one another.

As a next step, the core tool with profile shell and unidirectional area is guided through a cylinder die. The cylinder die is also preferably heated or a Heating device upstream. The cylinder die has a cylindrical cross section with a radius only slightly larger than the diameter of the core tool with profile shell and unidirectional area.

As a next step, the core tool with profile shell and unidirectional area is guided through a Faserpreformeinheit or Faserablegeeinheit for the cylinder shell, which applies the cylinder shell by means of winding and / or braiding. Again, depending on the application, the deposition of multiple fiber layers is conceivable, including a mixture of wound and braided layers, whereby the fiber angle may vary.

Subsequently, the profile shaft is consolidated in an RTM tool or a pultrusion unit. If a pultrusion unit is used, the method can be carried out continuously, but the shaft core should be removed in segments from the quasi-continuous semi-finished product after it has hardened, in order then to be returned to the beginning of the production line. The pultrusion unit according to the prior art consists of a pultrusion die which continuously infiltrates the fiber preform which slides through it with resin. If, instead of dry, only binded fibers or pre-impregnated fiber layers are used, the pultrusion only serves the necessary compression of Faserpreform and u.U. their heating to consolidation temperature. Preimpregnated fiber reinforcements include those semifinished fiber products which already contain the matrix, that is to say a suitable thermosetting resin system or in particular thermoplastic matrix material, in the required amount. The pultrusion nozzle is followed by a consolidation region in which either the thermoset-infiltrated preform is first cured under the influence of heat and then cooled or only cooled when using a thermoplastic matrix. Then a lengthening of the shaft main body to the desired final dimension and the core segment can be removed. In an RTM tool this is always filled in its length with the profiled shaft and allows infiltration with matrix material and its consolidation, with no feed takes place. Instead, before the vacuum-tight sealing of the RTM tool, the fiber preform must be separated at the appropriate point, so that the relevant core segment together with the associated fiber preform can be completely enclosed in the RTM tool.

Finally, there is still the separation of the profile shaft to the desired length and the removal of the core tool.

The profile shaft or the core tool is moved continuously or quasi-continuously during the process by means of a transport system.

Hereinafter, embodiments of the invention will be explained with reference to several figures. Showing:

1 an automobile drive shaft,

2 a representation of the layer structure of the profile wave 1 .

3 a representation of the load introduction element and its attachment,

4 a sectional view of the load introduction element 3 .

5 Examples of the geometric design of profiling of the profiled shaft,

6 an alternative load introduction element and its attachment,

7 a sectional view of the load introduction element 6 .

8th an alternative load introduction element and its attachment,

9 a sectional view of the load introduction element 8th .

10 an alternative load introduction element and its attachment,

11 a sectional view of the load introduction element 10 .

12 an alternative load introduction element and its attachment,

13 a sectional view of the load introduction element 12 .

14 an alternative load introduction element and its attachment,

15 a sectional view of the load introduction element 14 .

16 an alternative load introduction element and its attachment,

17 a sectional view of the load introduction element 16 .

18 a schematic diagram of a manufacturing unit for profile shafts according to the invention,

19 a schematic representation of an alternative manufacturing unit, and

20 a schematic diagram of another alternative manufacturing unit.

1 shows an embodiment of the invention, an automobile drive shaft 1 , This consists of a FKV profile shaft 2 , the outside with load introduction element 3 is connected, in turn, homokinetic joints 5 are arranged. On one side is in addition between load introduction element 3 and homokinetic joint 5 a ball-length compensation 4 intended.

The center is the FKV profile shaft 2 in 1 shown interrupted because the profile shaft 2 attached to a not shown here closer transmission or differential.

2 shows the closer structure of the profile shaft 2 , This has an inner profile shell 21 consisting of a first, inner layer 211 from a braided FRP layer with a fiber angle of 60 ° relative to the axial direction of the profiled shaft 2 and a second outer layer 212 also consisting of a braided FKV layer with a fiber angle of 45 ° with respect to the axial direction of the profiled shaft 2 , The fiber directions of the individual layers are also in the 2 indicated by arrows. The profile shell 21 has a profiling, with tooth heads 214 and feet 213 , where the tooth heads 214 protrude inward and thus form a recess on the outside.

Outwards to the profile shell 21 closes a unidirectional area 23 at. This unidirectional area 23 consists of unidirectional strips 231 made of FKV material with a fiber angle of 0 ° relative to the axial direction of the profile shaft 2 , The unidirectional strips 231 are in by the tooth heads 214 formed recesses, so that the unidirectional area 23 on the outside approximately forms a cylindrical shape.

Outside to the unidirectional area 23 closes a cylinder shell 25 at. Also the cylinder shell 25 consists of a first layer 251 made of FRP with plaited fiber reinforcement at an angle of 45 ° with respect to the axial direction of the profiled shaft 2 , The second layer 252 Also consists of braided FRP material with a fiber angle of 60 ° with respect to the axial direction of the profiled shaft 2 ,

Braided carbon fibers of type T 300 are used as fiber material. The matrix consists of an epoxy resin system with resin-hardener-accelerator components (resin: Araldite 564, hardener: Aradur 917 CH: accelerator: accelerator 960).

The wall thickness of the profile shaft 2 total is 4 mm (in the area of the tooth feet 213 ). Of this, 2 mm is accounted for by the profile shell 21 and 2 mm on the cylinder shell 25 , The unidirectional strips 231 have a center of 9mm thickness.

The transmittable dynamic torsional moment of the profile shaft is 1300 Nm and the transmittable static torsional moment 5100 Nm, with a weight of only 2200 g / m. The first bending natural frequency of the profile wave is 180 Hz with a length of approx. 1.2m, whereby the profile shaft is very well suited for machines with high speed.

3 shows a representation of the attachment of a load introduction element 6 in the profile shaft 2 , The load introduction element 6 has a mounting area 62 , for attachment of joints, gears u. Ä., And an externally profiled area 61 , wherein the outer profiling with the internal profiling of the profiled shaft 2 corresponds. The material of the load introduction element 6 is steel. For axial securing of the load introduction element 6 in the profile shaft 2 is in the profile shaft 2 a groove 71 Milled, which the profile shaft 2 in the area of the tooth feet ( 213 in 2 ) penetrates, wherein the externally profiled area 62 the load introduction element 6 corresponding to the groove 71 in the profile shaft 2 also has a broken groove. In this groove 71 becomes a circlip 72 inserted over the groove 71 the load introduction element 6 axially in the profile shaft 2 fixed. The circlip 72 may be, for example, a wet-wound ring or an elastically resilient ring.

4 shows the attachment of the load introduction element 6 in the profile shaft 2 corresponding 3 again in a sectional view. It is recognizable as the circlip 72 in the groove 71 in the load introduction element 6 intervenes.

5 shows alternative embodiments of the profile geometry of the profile shaft 2 or the load introduction element 6 , There are 81-84 possible variations of the profile shaft contour, depending on the mechanical design of the profile shaft 2 (To be transmitted torque, required portion of 0 ° oriented fiber layers to increase the natural frequency) and the resulting wall thickness, may have advantages. Such is a contour 82 at a particularly high required proportion of UD reinforcements and at an overall high wall thickness of the shaft of advantage, while a contour 84 more suitable for thin waves with a low proportion of 0 ° oriented fibers. profiles 81 or 83 represent a possible intermediate range with usual to higher wall thicknesses. The exact contour must be determined with suitable design calculations and can also manufacturing considerations for the metallic load introduction elements 6 consequences. Very Inexpensive, the required metallic component can be produced, for example, in the non-circular turning method, wherein the contour can then follow, for example, the laws of a hypocycloidal curve.

6 shows an alternative embodiment of the load introduction element 6 , which also has a mounting area 62 and a profiled area 61 having. 7 shows a sectional view of the load introduction element after 6 , The load introduction element 6 has barbs in the area of the depressions of its profiling 91 in small grooves 92 on the tooth heads ( 214 in 2 ) engage and the load introduction element 6 fix it axially.

8th and 9 show a further alternative embodiment of a load introduction element 6 , wherein this distributed over the circumference radial bores 63 having. For attachment is after insertion of the load introduction element 6 in the profile shaft 2 an inner ring 10 with spring elements 102 on which radial pins 101 sit through the holes 63 in the load introduction element 6 in a groove in the profile shaft 2 protrude and thus the load introduction element 6 fix axially. This alternative advantageously creates a detachable connection.

10 and 11 show a further alternative embodiment of the load introduction element 6 which of the alternative according to the 8th and 9 similar. It is in the area of the tooth feet ( 214 in 2 ) a variety of small barbs 11 arranged, which is an axial movement of the load introduction element 6 prevent.

12 and 13 show a further alternative embodiment, in which case outside the profile shaft 2 groove 121 and on the outside in the load introduction element 6 groove 122 are introduced. In these grooves 121 . 122 becomes a metal sleeve 12 plastically molded, so this with profiled shaft 2 and load introduction element 6 is positively connected and thus also connects to each other.

The 14 and 15 show a further possibility of connection of load introduction element 6 and profile shaft 2 , wherein the load introduction element 6 an externally molded, annular snap hook 131 and the profile shaft 2 has a corresponding recess. In addition, the profile shaft 2 inside a feather groove 132 that snaps the snap hook 131 facilitated in the corresponding recess. After snapping the connection is made by a locking sleeve 14 secured, in which case the profile shaft 2 can not expand to the outside and thus not from the snap hook 131 to solve. This connection is also solvable.

The attachment of the load introduction element 6 by bayonet connection to the profiled shaft 2 is through the 16 and 17 shown. For this purpose has the load introduction element 6 a bayonet ring 15 the several noses 152 having, during insertion of the load introduction element 6 in the profile shaft 2 moves in there introduced in the axial direction grooves, and secured at the end of these grooves by turning in a further, circumferentially extending groove. As anti-rotation then still safety pins 151 through the load introduction element 6 in holes in the profile shaft 2 brought in.

18 shows a system for manufacturing the profile shafts according to the invention 2 , In the figure on the left side is a divided core tool of a Faserpreformeinheit or Faserablegeeinheit for the profile shell 20 consisting of three braiding wheels 201 . 202 and 203 , fed. When braiding the profile shell 25 is in the Faserpreformeinheit or Faserablegeeinheit 20 That is, a thermosetting binder material, namely a powdered bisphenol A based solid epoxy resin component with the type designation 'XB3366' from Huntsman. Alternatively, it is also possible to use a thermoplastic binder yarn, for example based on PA. Subsequently, the profile shell 21 in a hot air blower 46 heated and through a profile die 41 led, which shapes the profiling. Through the hot air blower 46 , or through the profile die 41 , which can also be made heatable, the binder is melted and the profile shell 21 fixed. So can the dimensional accuracy of the profile shell 21 the profile shaft 2 be secured.

Subsequently, preconsolidated bars 40 made of FKV material with a unidirectional fiber reinforcement of the profiled shaft 2 about feeders 401 guided into the outer recesses of the profile shell. Then the passage of a cylinder die occurs 42 that the unidirectional strips 40 fixed. If necessary, the cylinder die can be preceded by another hot air blower. Now, the passage of the preform unit or Faserablegeeinheit for the cylinder shell takes place 30 , consisting of two braiding machines 301 and 302 that the cylinder shell 25 muster. The transport of the core tool through the system takes place by means of cable.

Then the profile wave 2 fed to a Resin Transfer Molding (RTM) tool. There, the matrix material, an epoxy resin mixture of Araldite 564, Aradur 917 CH and Accelerator 960 is added and the profile wave is consolidated by pressure and temperature. The RTM tool is a four-part metallic tool consisting of a top part, a bottom part and two side parts. After moving the profile shaft to be consolidated into the mounted upper and lower part of the RTM Tool is loosened the cable pulling device from the core tool and mounted the side panels. Subsequently, the closed RTM tool is evacuated and the liquid epoxy resin system is pressed in at a pressure of up to 6 bar. After hardening of the profile shaft by starting a temperature regime, the consolidated profile shaft after output can emerge from the shaft output 45 be removed from the mold. Then, if necessary, still grooves or the like for the attachment of load introduction elements introduce and then the profile shaft 2 used. The production of profile shafts 2 Thus, in this plant quasi-continuous, so feed takes place until the RTM tool is filled and subsequent standstill in the working phase of the RTM tool.

As materials of the profile shaft 2 A carbon fiber braided hose type T300, a thermosetting binder XB3366 and as matrix an epoxy resin mixture of Araldite 564, Aradur 917 CH and Accelerator 960 are used.

The 19 shows another method for producing a FKV profile wave, but which operates continuously. In contrast to the system according to 18 Here, however, the unidirectional area is not introduced in the form of preconsolidated strips, but via a coil unit 50 consisting of a first and a second creel 501 . 502 and a subsequent template 503 Thread the threads into the outer recesses of the profile shell 21 placed. By the laying of unidirectional strips 231 associated cooling is in front of the cylinder die 42 another hot air blower 46 intended. The Faserpreformeinheit / Faserablegeeinheit for the cylinder shell 30 is a Pultrusionseinheit downstream, the profile shaft first by a resin injection mold / feed unit of the matrix material 47 passed, then through a pultrusion nozzle 48 and finally by a heating unit 49 , Behind it is arranged a transport system 51 for the profile shaft 2 , Behind the transport system 51 there is a saw 52 that the profile shaft 2 separated in the desired length and then the split core tool 54 still to be taken.

Another alternative plant for the production of profiled FKV profile waves is in 20 shown. This system corresponds essentially to the system according to FIG 19 However, instead of the pultrusion unit, an RTM tool is used 44 for use. Again, the core tool is transported by cable through the system.

LIST OF REFERENCE NUMBERS

1

 drive shaft

2

 FRP profile shaft

21

 profile shell

211

 first shift

212

 second layer

23

 unidirectional area

231

 unidirectional strips

25

 cylindrical shell

251

 first shift

252

 second layer

3

 Load transfer area

4

 Ball length compensation

5

 homokinetic joint

6

 Load introduction element

61

 outside profiling

62

 fastening area

63

 drilling

71

 groove

72

 circlip

81

 profile geometry

82

 profile geometry

83

 profile geometry

84

 profile geometry

91

 barb

92

 groove

10

 inner ring

101

 radial pin

102

 spring element

11

 barb

12

 metal sleeve

121

 Groove in profile shaft

122

 Groove in the load introduction element

131

 snap hooks

132

 keyway

14

 securing sleeve

15

 bayonet ring

151

 safety pin

152

 nose

20

 Fiber preforming unit / fiber depositing unit profiled tray

201

 braiding

202

 braiding

203

 braiding

30

 Fiber preforming unit / fiber delivery unit Cylinder shell

301

 braiding

302

 braiding

40

 unidirectionally reinforced strips

401

 Feeding the strips 40

41

 Profilmatrize

42

 Zylindermatrize

43

 core feed

44

 RTM tool

45

 Shaft taking / sawing

46

 Heat Guns

47

 Preformer / Resin Injection Mold

48

 pultrusion die

49

 heating unit

50

 Coil unit unidirectional strips

501

 first creel

502

 second creel

503

 template

51

 transport system

52

 saw

53

 finished profile shaft

54

 shared core tool

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 19613857 [0005]

Claims (16)

Profile shaft ( 2 ) with an inner profile, made of fiber composite material, comprising at least three areas, in the radial direction of the profiled shaft ( 2 ) are arranged one above the other, wherein: - the first region is a profile shell ( 21 ), consisting of at least one layer ( 211 . 212 ) Fiber-reinforced plastic composite material with a fiber angle of ± 10 ° to ± 80 °, preferably ± 20 ° to ± 70 ° and more preferably ± 30 ° to ± 60 ° relative to the axial direction of the profiled shaft ( 2 ), wherein the profile shell ( 21 ) a profiled cross-section with tooth roots ( 213 ) and tooth heads ( 214 ), - the second area ( 23 ) is arranged outside of the first region and made of fiber-reinforced plastic composite material in a largely axial direction of the profiled shaft ( 2 ) arranged fibers, which formed by the profiling of the first region depressions / tooth heads ( 214 ), so that the outer contour of the second region is largely cylindrical, and - the third region is a cylindrical shell ( 25 ) and is arranged outside the second region, wherein the cylinder shell ( 25 ) of at least one layer ( 251 . 252 ) Fiber-reinforced plastic composite material with a fiber angle of ± 10 ° to ± 80 °, preferably ± 20 ° to ± 70 °, more preferably ± 30 ° to ± 60 ° relative to the axial direction of the profiled shaft ( 2 ) consists. Profile shaft ( 2 ) according to claim 1, characterized in that the profile shell ( 21 ) and / or the cylinder shell ( 25 ) consist of a braid, wherein preferably the profile shell ( 21 ) from a braid and the cylinder shell ( 22 ) consists of a winding. Profile shaft ( 2 ) according to one of the preceding claims, characterized in that the second region consists of over the circumference of the profiled shaft ( 2 ) distributed unidirectional strips ( 231 ) formed in the depressions / tooth heads ( 214 ) of the profile shell ( 21 ) are arranged. Profile shaft ( 2 ) according to one of the preceding claims, characterized in that the profile shell ( 21 ) of two layers ( 211 . 212 ), wherein the first, inner layer ( 211 ) a fiber angle to the axial direction of the profiled shaft ( 2 ) of 50 ° to 70 °, preferably 60 ° and the second, outer layer ( 212 ) a fiber angle to the axial direction of the profiled shaft ( 2 ) of 40 ° to 50 °, preferably 45 °. Profile shaft ( 2 ) according to one of the preceding claims, characterized in that the cylinder shell ( 25 ) of two layers ( 251 . 252 ), wherein the first, inner layer ( 251 ) a fiber angle to the axial direction of the profiled shaft ( 2 ) from 40 ° to 50 °, preferably 45 °, and the second, outer layer ( 252 ) a fiber angle to the axial direction of the profiled shaft ( 2 ) of 50 ° to 70 °, preferably 60 °. Profile shaft ( 2 ) according to one of the preceding claims, characterized in that in the profiled shaft ( 2 ) at least one load introduction element ( 6 ) is inserted, that one, to the internal profiling of the profiled shaft ( 2 ) corresponding external profiling ( 61 ), this external profiling ( 61 ) outside barbs in the area of the tooth head ( 214 ) and / or the tooth root ( 213 ), which the load introduction element ( 6 ) by hooking in the profile shaft ( 2 ) against slipping out in the axial direction ensures. Profile shaft ( 2 ) according to one of claims 1 or 2, characterized in that in the profiled shaft ( 2 ) at least one load introduction element ( 6 ) is inserted, that one, to the internal profiling of the profiled shaft ( 2 ) corresponding external profiling ( 61 ), and in addition to spring elements ( 102 ) mounted radial pins ( 101 ), which are in a groove ( 92 ) inside the profile shaft ( 2 ), so that the load introduction element ( 6 ) against slipping in the axial direction of the profile shaft ( 2 ) is secured. Profile shaft ( 2 ) according to one of the preceding claims, characterized in that in the profiled shaft ( 2 ) at least one load introduction element ( 6 ) is inserted, that a, to the internal profiling of the profile shaft corresponding outer profiling ( 61 ), wherein a sleeve ( 12 ) over the end piece of the profiled shaft ( 2 ) and part of the profile shaft ( 2 ) outstanding load introduction element ( 6 Is arranged) and engages there in radial grooves in the profiled shaft or the load introduction element, so that the load introduction element ( 6 ) positively with the profile shaft ( 2 ) connected is. Profile shaft ( 2 ) according to one of claims 1 or 2, characterized in that in the profiled shaft ( 2 ) at least one load introduction element ( 6 ) is inserted, that one, to the internal profiling of the profiled shaft ( 2 ) corresponding External profiling ( 61 ), wherein the external profiling ( 61 ) of the load introduction element has a ring which by an increase of the tooth heads ( 214 ) and / or the feet ( 213 ) is formed and a corresponding with the ring recess in the interior of the profile shaft ( 2 ) snaps, wherein after snapping the positive connection preferably by means of an applied after snapping safety sleeve ( 14 ) is secured against snapping. Profile shaft ( 2 ) according to one of claims 1 or 2, characterized in that in the profiled shaft ( 2 ) at least one load introduction element ( 6 ) is inserted, that one, to the internal profiling of the profiled shaft ( 2 ) corresponding external profiling ( 61 ), wherein in the profiled shaft ( 2 ) one in the region of the load introduction element ( 6 ) is introduced from the outside breaking groove through which the load introduction element is secured against axial slippage by means of a ring engaging in the apertures. Profile shaft ( 2 ) according to one of claims 1 or 2, characterized in that in the profiled shaft ( 2 ) at least one load introduction element ( 6 ) is inserted, that a, to the internal profiling of the profile shaft corresponding outer profiling ( 61 ), wherein the load introduction element ( 6 ) a rotatable bayonet ring ( 15 ) with noses ( 152 ), which in an axial inside groove in the profiled shaft ( 2 ) are insertable and then by twisting the bayonet ring ( 15 ) in a subsequent to the axial groove radial groove the load introduction element ( 6 ) is secured against axial displacement. Method for producing a profiled shaft ( 2 ) according to one of claims 1 or 2, comprising the following method steps: a) performing a split core tool ( 54 ) with a corresponding with the desired inner profile of the profile shaft outer profile by a Faserpreformeinheit / Faserablegeeinheit for the profile shell ( 20 ), whereby these on the core the profile shell ( 21 ) of the profiled shaft ( 2 ) by means of braiding and / or winding, b) performing the core tool ( 54 ) with the profile shell ( 21 ) by a profile die ( 41 ), which is preferably heatable or preferably a heating device is upstream, c) introducing the second region, namely of FKV material with a fiber direction which largely the axial direction of the profile shaft ( 2 ) corresponds, in the recesses of the profile shell ( 21 ) through the tooth heads ( 214 ), d) performing the core tool ( 54 ) with profile shell ( 21 ) and unidirectional area ( 23 ) by a cylinder die ( 41 ), which is preferably heatable or preferably preceded by a heating device, e) performing the core tool ( 54 ) with profile shell ( 21 ) and unidirectional area ( 23 ) by a Faserpreformeinheit / Faserablgeeinheit for the cylinder shell ( 30 ), wherein the cylinder shell ( 25 ) is applied by means of winding and / or braiding, f) consolidating the profiled shaft ( 2 ) in an RTM tool ( 44 ) or a pultrusion unit ( 47 . 48 . 49 ), and g) severing the profiled shaft ( 2 ) in the desired length and removal of the core tool ( 54 ), wherein the profiled shaft ( 2 ) or the core tool ( 54 ) by means of a transport system ( 51 ) are moved continuously or quasi-continuously. A method according to claim 12, characterized in that the Faserpreformeinheit / Faserablegeeinheit for the profile shell ( 20 ) and / or the Faserpreformeinheit / Faserablgeeinheit for the cylinder shell ( 30 ) apply a plurality of layers of fibers, which preferably have a varying fiber angle. A method according to claim 12 or 13, characterized in that during step a) or directly after the profile shell ( 21 ) a binder material, preferably powder or yarn, is added. Method according to one of claims 12 to 14, characterized in that in step c) preconsolidated unidirectional strips ( 231 . 40 ) are introduced. Method according to one of claims 12 to 14, characterized in that in step c) by means of a coil unit ( 50 ) and a subordinate template ( 503 ) the fibers for the unidirectional region ( 23 ) are introduced.

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