DE102015225656A1 - Method for producing a fiber-reinforced hollow profile component - Google Patents

Abstract

According to the invention, a method is provided for producing a fiber-reinforced hollow profile component (1), the method having the following steps: - building up negative pressure in a closed molding section (114) of a forming space (113) bounded by a vacuum film (112), in which a forming structure (20) is located, wherein in the forming section (114) a fibrous layer (2) is located, wherein the forming structure (20) has a forming inner core (21) consisting of a foam core part (22) and a along a fiber layer longitudinal direction (L2) extending and the foam core part (22) in the fiber layer circumferential direction (U2) at least partially enclosing and formed on this separation film (23) is formed by - creating negative pressure in the forming section (114) Introducing matrix material into the forming section (114) through a supply opening (118), by applying temperature at a predetermined temperature area over a given period hardening of the matrix material and thereby forming a component interior (IR) defining the component wall (4) with a matrix material layer (3) containing the fiber layer (2), - removing at least the foam core part (22) from the component interior (IR).

Description

The invention relates to a method for producing a fiber-reinforced hollow profile component, in particular a hollow profile component for a motor vehicle.

Fiber-reinforced hollow profile components are used in motor vehicles in particular as structural components for the roof construction. Therefore, these components must meet high demands on the mechanical strength on the one hand. In addition, requirements for low component weight are increasingly being made in ground vehicles as well.

From the general state of the art, it is known to use a vacuum method for the production of fiber-reinforced hollow profile components.

It is an object of the present invention to provide a method by which a fiber-reinforced hollow profile component with high quality and low weight can be produced in an efficient manner.

This object is achieved in each case by a method having the features of the independent claims. Further advantageous embodiments are specified in the dependent on these subclaims.

• – Formungsraum Aufbauen von Unterdruck in einem geschlossenen Formungsabschnitt eines durch eine Vakuumfolie begrenzten Formungsraums, in dem ein Formungsgebilde gelegen ist, wobei der Formungsabschnitt zwischen dem Formungsgebilde und der Vakuumfolie gelegen ist und in dem Formungsabschnitt eine Faserschicht gelegen ist, die sich an dem Formungsgebilde anliegend in einer Faserschicht-Längsrichtung erstreckt und dieses in einer quer zu dieser gerichteten Faserschicht-Umfangsrichtung umschließt, wobei das Formungsgebilde einen Formungs-Innenkern aufweist, der aus einem Schaumkern-Teil und einer sich entlang der Faserschicht-Längsrichtung erstreckenden und das Schaumkern-Teil in der Faserschicht-Umfangsrichtung zumindest abschnittsweise umschließenden und an diesem anliegenden Trennfolie gebildet ist,
• – durch Entstehen von Unterdruck in dem Formungsabschnitt Einführen von Matrix-Material durch eine Zufuhröffnung in den Formungsabschnitt,
• – durch Anlegen von Temperatur in einem vorgegebenen Temperaturbereich über einen vorgegebenen Zeitraum Härten des Matrix-Materials und dadurch Ausbildung einer einen Bauteil-Innenraum definierenden Bauteilwandung mit einer Matrix-Materialschicht, die die Faserschicht enthält,
• – Entfernen zumindest des Schaumkern-Teils aus dem Bauteil-Innenraum.

According to the invention, a method is provided for producing a fiber-reinforced hollow profile component, the method having the following steps:

• - Forming space In a closed forming section of a vacuum film limited molding space in which a forming structure is located, wherein the forming portion between the forming structure and the vacuum film is located and in the forming section, a fiber layer is located, which is adjacent to the forming structure in extending longitudinally in a fibrous layer longitudinal direction and enclosing the same in a fiber-layer circumferential direction transverse thereto, the forming structure having a forming inner core consisting of a foam core portion and one extending along the fiber layer longitudinal direction and the foam core portion in the fibrous layer -Umfangsrichtung at least partially enclosing and formed on this separation film is formed,
• By introducing negative pressure in the molding section, introduction of matrix material through a supply opening into the molding section,
• Curing the matrix material by applying temperature in a predetermined temperature range over a predetermined period of time and thereby forming a component wall defining a component interior with a matrix material layer containing the fiber layer,
• - Remove at least the foam core part from the component interior.

In this case, the shaping structure of fibers forming the fibrous layer can in particular be wrapped around, wrapped around, braided over.

• – Aufbauen von Unterdruck in einem geschlossenen Formungsabschnitt eines durch eine Vakuumfolie begrenzten Formungsraums, in dem ein Formungsgebilde gelegen ist, wobei der Formungsabschnitt zwischen dem Formungsgebilde und der Vakuumfolie gelegen ist und in dem Formungsabschnitt eine aus Verstärkungsfasern und Matrixmaterial gebildete Faserschicht gelegen ist, die sich an dem Formungsgebilde anliegend in einer Faserschicht-Längsrichtung erstreckt und dieses in einer quer zu dieser gerichteten Faserschicht-Umfangsrichtung umschließt, wobei das Formungsgebilde einen Formungs-Innenkern aufweist, der aus einem Schaumkern-Teil und einer sich entlang der Faserschicht-Längsrichtung erstreckenden und das Schaumkern-Teil in der Faserschicht-Umfangsrichtung zumindest abschnittsweise umschließenden und an diesem anliegenden Trennfolie gebildet ist,
• – durch Anlegen von Temperatur in einem vorgegebenen Temperaturbereich über einen vorgegebenen Zeitraum Härten des Matrix-Materials und dadurch Ausbildung einer einen Bauteil-Innenraum definierenden Bauteilwandung mit einer Matrix-Materialschicht, die die Faserschicht enthält,
• – Entfernen zumindest des Schaumkern-Teils aus dem Bauteil-Innenraum.

According to the invention, a method is also provided for producing a fiber-reinforced hollow profile component, which has the following steps:

• Forming negative pressure in a closed forming section of a vacuum film confined forming space in which a forming formation is located, the forming section being located between the forming structure and the vacuum film, and in the forming section being located a fibrous layer formed of reinforcing fibers and matrix material adhering to extending in a fiber layer longitudinal direction adjacent the forming structure and enclosing the same in a fiber layer circumferential direction directed transversely thereto, the forming structure having a forming inner core comprising a foam core portion and a fiber longitudinal direction extending along the fiber layer longitudinal direction; Part in the fiber layer circumferential direction at least partially enclosing and formed on this separation film is formed,
• Curing the matrix material by applying temperature in a predetermined temperature range over a predetermined period of time and thereby forming a component wall defining a component interior with a matrix material layer containing the fiber layer,
• - Remove at least the foam core part from the component interior.

In one embodiment of this method according to the invention, it is provided that matrix material is introduced into the molding section through a feed opening by the formation of negative pressure in the molding section.

In any of the methods of the invention, the forming or semi-finished product may be completely enclosed by the vacuum film or may be partially enclosed by a support, e.g. may be limited by a tool part.

In each of the inventive method can be provided that the release film of the Shaping inner core rests against the fiber layer over its entire extent.

Alternatively, it can be provided in each of the inventive method that the release film of the inner core molding is surrounded over its entire extent by a mold core intermediate structure, which is located between the release film and the fiber layer and rests against these in each case over its entire extent.

According to a further alternative, it can be provided in each of the inventive methods that the release film in at least a first fiber layer contact portion rests against the fiber layer and at least one mold core intermediate structure in a respective, with respect to the fiber layer longitudinal direction laterally of the first fiber layer contact portion lying second fiber layer-contact portion abuts the fiber layer, wherein the mold core intermediate structure between the release film and the fiber layer is also disposed adjacent thereto.

In each of the methods according to the invention, it may further be provided that the removal of the foam core part takes place by pulling it out of the component interior and then removing the separating film from the component interior.

Alternatively, it can be provided in each of the methods according to the invention that the removal of the foam core part takes place by simultaneous extraction of the foam core part and the release film.

According to a further alternative, it may be provided in each of the methods according to the invention that the removal of the foam core part takes place by abrasive removal with a gas-solid jet.

According to a further additional alternative, it can be provided in each of the methods according to the invention that the removal of the foam core part takes place by chemical dissolution with a solvent.

If the removal of the foam core part takes place by means of abrasive removal or chemical dissolution with a solvent, provision may also be made for the release film to be removed from the component interior after removal of the foam core part.

Furthermore, in each of the methods according to the invention, it can be provided that the shaping inner core has a foam core part composed of a plurality of foam core sections.

If the release film rests against an intermediate structure, it may be provided that the mold core intermediate structure is formed from a plurality of intermediate parts.

If the release film rests against an intermediate structure, it may further be provided that the mold core intermediate structure comprises at least one intermediate core part and an intermediate structure extending along the fiber layer longitudinal direction and enclosing the respective intermediate core part in the fiber layer circumferential direction Separating film is formed.

• (a) das Schaumkern-Teil,
• (b) das Zwischengebilde.

In each of the methods according to the invention it can be provided that one or more of the following components are formed from a rigid foam material:

• (a) the foam core part,
• (b) the intermediate structure.

• – Copolymer-Material,
• – Polyamid oder Polyamid-Mischungen,
• – Polyolefine,
• – Polyurethan,
• – Teflon,
• – Polyether-Blockamide,
• – Polyethylenterephthalat,
• – Polyvinylchlorid-Folien,
• – Nylon.

Furthermore, it can be provided in each of the methods according to the invention that the release film is formed from or comprises one or more of the following materials:

• Copolymer material,
• - polyamide or polyamide mixtures,
• - polyolefins,
• - polyurethane,
• - Teflon,
• - polyether block amides,
• - polyethylene terephthalate,
• - polyvinyl chloride films,
• - Nylon.

The term "along" may be used herein in connection with the directional information referred to herein that may relate to the contour of a contour line or a surface, or may relate to a direction of a mechanical component such as an axle or shaft, in particular mean that the tangent to the respective contour line or to the respective surface in the course according to the direction or the longitudinal extent and eg center axis of the mechanical component locally deviates from a reference direction or reference axis with an angle of at most 45 degrees and preferably of at most 30 degrees to which the respective indication of direction is related.

The term "transverse" herein may in particular mean that the tangent to the respective one of the directional indications referred to herein, which may concern the course of a contour line or a surface, or which may relate to a direction of a mechanical component such as an axle or shaft Contour line or to the respective surface in its course according to the direction or the longitudinal extent and eg Center axis of the mechanical component locally deviates at an angle of at least 45 degrees, and preferably of at least 30 degrees from a reference direction or reference axis, to which or the respective direction indication is related.

By "fibers" is meant herein in particular reinforcing fibers which have a substantial influence on its strength in a component.

Embodiments of the invention will now be described with reference to the accompanying drawings. It shows:

1 a sectional view through a manufacturing device during the implementation of a first step of the inventive method for producing a fiber-reinforced hollow profile component according to a first embodiment, wherein the manufacturing device is a matrix material supply line for supplying matrix material in a forming space in which a fiber layer located is, has,

2 a sectional view through a to the in the 1 during a first step of the method according to the invention for producing a fiber-reinforced hollow profile component according to a second embodiment, wherein the production device does not have a matrix material supply line for feeding matrix material into a forming space in which a fibrous layer is located, having,

3 a sectional view of an intermediate product for forming the hollow-profile component after removal from the manufacturing device of 1 or the 2 .

4 a last step of the method according to the invention, in which removal of a foam core part takes place from a component interior of the hollow profile component,

5 the removal of the foam core part from the component interior in one of the in 4 shown alternative way

6 a sectional view of a hollow profile component produced by the method according to the invention,

7 a sectional view through a manufacturing device during the implementation of a first step of a second embodiment of the inventive method for producing a fiber-reinforced hollow profile component, wherein the manufacturing device is a matrix material supply line for supplying matrix material in a forming space in which a fiber layer is located , having

8th a sectional view of a according to the in 7 embodiment shown produced intermediate product for forming the hollow profile component after removal from the manufacturing device,

9 the removal of the foam core part from the component interior of the according to the in 7 shown embodiment produced intermediate,

10 the removal of the foam core part from the component interior in one of the in 9 shown alternative way

11 a sectional view of a hollow profile component produced according to the second embodiment of the method according to the invention,

12 1 is a sectional view of an intermediate product according to a third embodiment for forming the hollow profile component after opening the molding tool device;

13 the removal of the foam core part from the component interior of the intermediate product 14 .

14 a sectional view of a hollow profile component produced according to the third embodiment of the method according to the invention,

15 1 a sectional view of an intermediate product according to a variant of the first embodiment for forming the hollow profile component after removal from the molding tool device,

16 the removal of the foam core part from the component interior of the intermediate product 15 .

17 a sectional view of one of the variant of the first embodiment according to the 15 of the inventive method produced hollow profile component.

1 shows a first step of a method according to the invention for producing a fiber-reinforced hollow profile component 1 , In this step, in a molding section 114 one through a vacuum film 112 limited molding space 113 Negative pressure generated and thereby over a Matrix material supply line 116 a matrix material in the forming section 114 introduced.

When in the 1 shown embodiment of the manufacturing device, this has a first tool part 11 and a vacuum foil 112 on. The first tool part 11 has a tool contour surface 11a into which a depression 11b is trained. On the first tool part 11 is a second tool part in the form of a vacuum film 112 located with the first tool part 11 in a circumferential sealing area 112b tight, in particular fluid-tight, is connected, so that the inner surface 112a with the tool contour surface 11a a shaping space 113 form. The vacuum film 112 can in the sealing area 112b for example, by an adhesive with the first tool part 11 be connected. It can also be provided that the vacuum film 112 with a clamping device, for example in the form of a frame, to the first tool part 11 is pressed or clamped to this. The inner surface 112a the vacuum film 112 is the tool contour surface 11a oriented towards. In particular, define the tool contour surface 11a and the inner surface 112a the vacuum film 112 an outer surface 1a of the produced hollow profile component 1 , In the molding room 113 is a formation 20 located. When in the 1 The embodiment shown is the forming structure 20 partly in the depression 11b located. This defines a closed inner surface 1b of the produced hollow profile component 1 ,

The shaping section 114 is between the formation 20 and a forming section bounded from the tool contour surface 11a as well as an investment section 112c the vacuum film 112 that of the sealing area 112b the same is formed, is formed, so that the shaping section 114 especially between them. In particular, the molding section extends 114 between an outer surface 20a of the formation 20 and the forming section boundary from the tool contour surface 11a and the investment section 112c the vacuum film 112 ,

As in the 1 and 7 shown has the manufacturing device 110 one in the forming room 113 and in particular in the forming section 114 opening matrix material supply line 116 on, like in the 1 and 6 shown through the vacuum film 112 and in particular the plant section 112c the vacuum film 112 flows through. Alternatively or additionally, it may be provided that the matrix material supply line 116 through the tool part 11 extends through and through the tool Kontouroberfläche 11a in the forming room 113 opens. To the material supply line 116 is a material supply device (not shown), for example in the form of a matrix material reservoir, connected, which may have a valve to the supply of matrix material in the forming space 113 in the locked state to prevent and allow in the open state. Furthermore, the manufacturing device 110 a vacuum line 119 on top of that in the shaping section 114 opens, with the vacuum line 119 across the contact section 112c the vacuum film 112 or the tool part 11 extends through and through the tool Kontouroberfläche 11a in the forming room 113 opens. Through the vacuum line 119 can negative pressure at the forming section 114 be created, which over the matrix material supply line 116 in the molding section 114 is sucked in and can occur.

In the embodiments of the manufacturing device according to the invention, in each case additionally a semi-permeable membrane (not shown) between the fiber layer 2 and the vacuum film 112 be arranged, wherein the matrix material supply line 116 across the vacuum film 112 extends through and in a corresponding opening of the semi-permeable membrane in the molding section 114 opens. In this embodiment, the vacuum line opens 119 in the vacuum film 112 in the space between the vacuum film 112 and the semi-permeable membrane. The vacuum film 112 can in another sealing area on the tool 11 opposite the tool 11 to be sealed. Alternatively or additionally, the vacuum film may 112 opposite the vacuum foil 112 be sealed in sections or enclosing.

To enter the matrix material in the molding section 114 is done by sucking air through the vacuum line 119 from the molding section 114 generated in this negative pressure and the valve, for example, opened by means of a control device, so that the supply of liquid matrix material through the material supply line 116 in the molding section 114 can be done. The mold device 10 In addition, at least one material receiving device 117 to contain excess matrix material.

In the molding section 114 is how in 1 shown a fiber layer 2 located. This extends in a fiber layer longitudinal direction L2 and encloses the shaping structure 20 in a fiber layer circumferential direction U2 directed transversely to the fiber layer longitudinal direction L2. This is the fiber layer 2 on the forming structure 20 at. In particular, the fiber layer lies 2 flat on the outer surface 20a of the formation 20 at. By applying negative pressure in the forming section 114 over the vacuum line 119 the investment section lays down 112c the vacuum film 112 to the fiber layer 2 and can perform a shaping function.

In the manufacturing device, the tool part 11 be designed as a support device and eg as a support plate (not shown), so that the shaping structure 20 not partially from a depression 11b is included. In this case, the connection section 11b located on the support plate and the contact section 112c encloses airtight a larger area of the forming structure 20 , It can also be provided that the vacuum film 112 the forming structure 20 completely encloses or only in a longitudinal section of the forming structure 20 completely encloses.

The fiber layer 2 is formed of a plurality of fibers, in particular reinforcing fibers. In particular tensile and stiff fibers can be used as fibers. The reinforcing fibers may be or consist of one or more of the following: amide, aramid, glass, carbon, silicon, boron or graphite. The fibers may each extend in the fiber layer circumferential direction U2 or in the fiber layer longitudinal direction L2. Also, individual fibers may extend in the fiber layer circumferential direction U2 and individual filaments in the fiber layer longitudinal direction L2.

The arrangement of the fibers may be such that it has at least a portion of the outer surface 20a of the formation 20 at least partially wrap or umweben or entwine. Also, the fibrous layer may be formed of at least a first fiber sublayer in which the fibers wrap around the subsection and at least one of the outer surface 20a may be formed above or below the first fiber layer located second fiber sub-layer, in which the fibers umweben the subsection.

The section of the outer surface 20a or the entire outer surface 20a can be designed as a convex shape at least partially or over its entire planar extension shaped surface.

The fibers may also be at least partially formed into rovings, so that the rovings form the surface 20a at least partially wrap around and / or umweben and / or entwine.

The fiber layer 2 can be by winding, braiding or weaving the fibers or rovings as dry fiber material on the outer surface 20a of the formation 20 be formed. When using dry fiber material may be provided that this before the introduction of the same in the mold device 10 is provided with matrix material. In this case, it may be provided, for example, that the dry fiber material is passed through an impregnating bath with matrix material or provided with matrix material, for example by wetting or spraying.

Alternatively or in addition to these embodiments, the fibrous layer 2 be created by applying at least one flat, ie flat or band-shaped or mat-shaped overlay of dry fiber or prepreg material. When using prepreg semifinished products, ie with a matrix material preimpregnated semi-finished fiber assemblies, the textile fibers or scrims are already provided with matrix material. In this embodiment of the method according to the invention, a manufacturing device 110 be used, no matrix material supply line 116 as they are close in the manufacturing device 1 is provided has.

The 2 shows a first step of a method according to the invention for producing a fiber-reinforced hollow profile component 1 with such a manufacturing device 110 without matrix material supply line 116 , In this step, in a molding section 114 one through a vacuum film 112 limited molding space 113 Negative pressure generated and thereby over a matrix material supply line 116 a matrix material in the forming section 114 introduced.

Furthermore, a selection or combination of rovings, fabrics, fabrics, prepregs and / or filaments may be used as a semi-finished product.

As a matrix material 2 In general, resins or thermosetting materials such as unsaturated polyester resins (UP), epoxy resins (EP) or vinyl esters (VE) or thermoplastic materials such as polypropylene (PP), polyamide (PA), polyetheretherketone (PEEK) can be used. Also, as a matrix material, a molten metal can be used.

In the figures, the fiber layer 2 shown only schematically, the individual fibers are shown for clarity with a relation to the component dimensions too large diameter and in too small a number.

The forming structure 20 generally has a forming inner core 21 on, made of a foam core part 22 and a voltage applied to this release film 23 is formed. The release film 23 extends along the fiber layer longitudinal direction L2 and encloses the foam core part 22 in the fiber layer circumferential direction U2 at least sections. This is the release film 23 in particular with an inner surface 23a on an outer surface 22a the foam core part 22 at.

The release film 23 can be made up of a plurality of separating film sections that are juxtaposed and, in particular, adjoining one another with respect to the fiber layer longitudinal direction L2 or the fiber layer circumferential direction U2. However, it may also be advantageous for the separating film sections to be located at a distance from each other with respect to the fiber layer longitudinal direction L2 or the fiber layer circumferential direction U2.

Advantageously, it can be provided that the release film 23 over the entire longitudinal extent of the foam core part 22 along the fiber layer longitudinal direction L2 extends. This is the release film 23 with the inner surface 23a especially on the outside surface 22a of the foam core part 22 in that, with respect to the fiber layer longitudinal direction L2, the outer surface 22a total is covered. Preferably, the release film extends 23 thereby continuously along the fiber layer longitudinal direction L2 over the foam core part 22 , Furthermore, it can be provided that the release film 23 only in sections on the foam core part 22 extends, especially if the release film 23 for example, has recesses on the edge or in the inner region.

Alternatively, the release film may 23 with respect to the longitudinal extent only over one or more individual sections in the longitudinal extent of the foam core part 22 , For example, over 70% of the longitudinal extent, extend. In this case it can be provided that separating film with respect to the fiber layer longitudinal direction L2 over a central portion of the longitudinal extent of the foam core part 22 - For example, 80% - extends, while at with respect to the fiber layer longitudinal direction L2 side of the central portion located end portions of the foam core part 22 - For example, each 10% - not from the release film 23 are covered. It can also be provided that the release film 23 from one of the end portions of the foam core part 22 from over part of the longitudinal extent of the foam core part 22 extends and the opposite end portion of the foam core part 22 not from the release film 23 is covered. In particular, the release film can 23 or the release film section thereby extend in the respective section continuously along the fiber layer longitudinal direction L2. Furthermore, the release film 23 or the release film portion also extend only partially in the respective section when the release film 23 or the release film section, for example, has recesses.

With respect to the fiber layer circumferential direction U2, the release film encloses 23 or optionally, the release film sections enclose the foam core portion 22 all in all. Alternatively, it can also be provided that the release film 23 in the fiber layer circumferential direction U2 only over a peripheral portion of the foam core part 22 extends. In particular, the release film can 23 or the release film section thereby extending in the respective peripheral portion continuously along the fiber layer circumferential direction U2. Furthermore, the release film 23 or the release film portion also extend only partially in the respective section when the release film 23 or the release film section, for example, has recesses.

The release film 23 can with the foam core part 22 be connected, in particular flat, for example by means of a between the foam core part 22 and the release film 23 applied adhesive. It can also be provided that the release film 23 only loose on the foam core part 22 is present and held on this example, non-positively. This can be realized by the release film 23 such on the foam core part 22 pulled up or shrunk on that is the inner surface 23b the release film 23 a pressure on the outer surface 22a of the foam core part 22 exercises.

The release film 23 may in particular be formed from a copolymer material or generally from a plastic material. In particular, films of polyamide, polyamide mixtures, polyolefins or the like come into consideration. Furthermore, polyurethane films (PU films), Teflon films (PTFE films), polyether block amide films, polyethylene terephthalate films (PET films), polyvinyl chloride films (PVC films) or the like can be used. Also nylon films come as a release film 23 into consideration. When using one or more of these materials, the release film will conform 23 very good the contour of the outer surface 22a the foam core part 22 and thus an optimized manufacturing process can be ensured.

In particular, films of polyamide, polyamide blends, polyolefins or nylon have a particularly high elasticity and extensibility with good power transmission. For example, the film may have an elongation at break relative to the original length of the film between 80% and 800%, in particular between 80% and 300%, preferably between 90% and 150% and particularly preferably between 90% and 120%. These characteristic values can, for example, according to Standard ASTM D882 be determined.

The release film 23 may have a thickness in the range between 10 μm and 3 mm.

The foam core part 22 may in particular be formed as a longitudinally extending body, for example, has a circular, elliptical, rectangular or polygonal cross-sectional shape. In particular, the foam core part 22 be formed as a cylindrical body, as a truncated cone or generally as a along the fiber layer longitudinal direction L2 tapering body. With a tapered shape, a larger space can be filled locally than with a cylindrical shape. At the same time, the foam core part 22 easier to be removed from the component interior IR. Removing the foam core part 22 will be described in detail below.

As in 1 can be shown, the forming inner core 21 only a single foam core part 22 exhibit. It can also be provided that the shaping inner core 21 , as in 15 shown, from several foam core sections 34 . 35 . 36 that the foam core part 22 train, is composed. For example, a plurality of foam core sections may be arranged one behind the other in relation to the fiber layer longitudinal direction L2.

The foam core part 22 is preferably formed from a rigid foam material, such as a polyurethane foam material. Hard foam materials offer the advantage that these on the one hand for the shaping of the hollow profile component 1 necessary dimensional stability and at the same time have a low weight. Also, hard foam materials, as will be described in detail later, after formation of the walls of the hollow profile component 1 easily remove from this.

According to a first embodiment of the method according to the invention, which in the 1 to 6 such as 15 and 16 is shown, the release film lies 23 with the outer surface 23a over its entire extent in the fiber layer longitudinal direction L2 at the fiber layer 2 at. In this case, the outer surface forms 23a the release film 23 the outer surface 20a of the formation 20 , In the case that the release film 23 only over a portion of the longitudinal extent of the foam core part 22 extends, lies the fiber layer 2 in a first section on the release film 23 and in a laterally located portion on the outer surface with respect to the fiber layer longitudinal direction L2 22a the foam core part 22 at. Here is the outer surface 20a of the formation 20 in sections through the outer surface 22a the foam core part 22 and the outer surface 23a the release film 23 educated.

According to a second embodiment of the method according to the invention, which in the 7 to 11 is shown is the release film 23 over its entire extension of a mold core intermediate structure 24 surrounded, between the release film 23 , in particular between their outer surface 23a and the fiber layer 2 is located. In this case, the intermediate structure lies 24 in each case over the entire extension of the fiber layer 2 at. The intermediate structure 24 is generally designed such that this depends on the course, in particular the curvature of the component wall to be formed 4 of the produced hollow profile component 1 extending between the forming inner core 21 and the fiber layer 2 fills the extending gap ZR. In particular, in this embodiment, the intermediate structure defines 24 the curvature of the component wall 4 of the produced hollow profile component 1 ,

The mold core intermediate structure 24 can generally, as in the 7 to 10 and 12 to 14 shown from several intermediate parts 25 . 26 . 27 be composed or formed. It can also be provided that the intermediate structure 24 is executed as a single part, as in 14 , Furthermore, it can be provided that the intermediate structure 24 or the individual intermediate parts 25 . 26 . 27 , similar to the forming core 21 , from an intermediate core part 28 . 30 . 32 and an interlayer release film 29 . 31 . 33 are composed. It can be provided that the intermediate structure release film 29 . 31 . 33 extends along the fiber layer longitudinal direction L2 and the respective intermediate core part 28 . 30 . 32 in the fiber layer circumferential direction U2 at least partially surrounds and rests against this. The mold core intermediate structure 24 or optionally the individual intermediate parts 25 . 26 . 27 are like the foam core part 22 , preferably made of a rigid foam material, for example a polyurethane foam material formed.

According to the in the 7 to 10 shown variant of the second embodiment is the intermediate structure 24 from the three intermediate parts 25 . 26 . 27 composed of the molding core 21 each partially surrounded in the fiber layer circumferential direction U2. Each of the interpiece parts 25 . 26 . 27 lies with an inner surface 25a . 26a . 27a at a portion of an outer surface 23a the release film 23 at. In the in the 7 to 10 variant shown are the intermediate parts 25 and 26 each wedge-shaped. The intermediate part 27 joins in the fiber layer circumferential direction U2 to the intermediate structure parts 25 and 26 and is designed as an elongated body. Furthermore, the intermediate parts 25 . 26 . 27 each from an intermediate core part 28 . 30 . 32 and an interlayer release film 29 . 31 . 33 composed. The intermediate structure core part 28 and 30 the intermediate parts 25 and 26 each of the fiber layer circumferential direction U2 is completely separated from an interlayer release film 29 respectively. 31 surround. The inner surfaces 25a and 26a the wedge-shaped intermediate parts 25 and 26 in this case are thus each by a surface of the respective intermediate structure release film 29 respectively. 31 educated. The intermediate structure core part 32 of the intermediate part 27 is only on one of the fiber layer facing outer surface, opposite to the inner surface 27a of the intermediate part 27 forming surface of the intermediate structure core part 32 is located, from an interlayer release film 33 surround. The release film 23 is thus over its entire extension of the intermediate parts 25 . 26 and 27 forming the molding intermediate 24 train, surrounded. The intermediate parts 25 . 26 and 27 are therefore between the release film 23 , in particular between their outer surface 23a and the fiber layer 2 and to each of these over their entire extension. In particular, the outer surfaces form 29b . 31b and 33b the interlayer release films 29 . 31 . 33 the intermediate parts 25 . 26 and 27 together the outer surface 20 of the formation 20 at which the the fiber layer 2 is applied.

Thus, in the in the 7 to 10 shown variant of the second embodiment of the method according to the invention, the release film 23 over its entire extension of a mold core intermediate structure 24 surrounded, between the release film 23 and the fiber layer 2 is located and at these in each case over their entire extent rests.

According to a third embodiment of the method according to the invention, which in the 12 to 14 is shown, the release film lies 23 in at least a first fibrous layer contacting section 2a at the fiber layer. Furthermore, there is at least one mold core intermediate structure 24 in a respective, with respect to the fiber layer longitudinal direction L2 side of the first fiber layer abutment portion 2a located second fiber layer plant section 2 B at the fiber layer 2 at. This second fiber layer contact section 2 B is in particular outside of the first fiber layer contact section 2a located. The mold core intermediate structure 24 is also in this embodiment between the release film 23 , in particular between their outer surface 23a and the fiber layer 2 located and is attached to each of these. The intermediate structure 24 is formed such that this depends on the course, in particular the curvature of the component wall 4 of the produced hollow profile component 1 extending between the forming inner core 21 and the fiber layer 2 fills the extending gap ZR. In particular, in this embodiment, the intermediate structure defines 24 outside of the first fiber layer abutting section 2a the curvature of the component wall 4 of the produced hollow profile component 1 ,

The 12 to 14 show a variant of the third embodiment, according to which the mold core intermediate structure 24 as the only intermediate part 27 is formed and in the present case has no intermediate structure release film. The release film 23 lies with a section of the outer surface 23a at the first fiber layer abutting section 2a the fiber layer 2 at. In particular, the first fiber layer contact section 2a in the fiber layer longitudinal direction L2 has a certain length ML2. This can be very short, so that the first fiber layer contact section 2a is designed only as a contact point. Furthermore, the first fiber layer contact section extends 2a also at least partially in the fiber layer circumferential direction U2. Outside the section of the outer surface 23a at the first fiber layer contact section 2a is present, lies the release film 23 with the outer surface 23a on the inner surface 27a of the intermediate part 27 at.

In general, the shape, in particular the length ML2 of the first contact section 2a depending on the Kontourverlauf the component wall to be produced 4 , For example, in the case of a strongly curved course, that is to say with a small radius of curvature, a short first contact section with respect to the fiber layer longitudinal direction L2 can be used 2a result. In the case of a curve that is only slightly curved, that is to say in the case of a large radius of curvature, a relatively long first contact section can be formed with respect to the fiber layer longitudinal direction L2 2a result.

As the 12 to 14 continue to show, lies the intermediate part 27 at a side relative to the fiber layer longitudinal direction L2 and in particular outside the first fiber layer abutment portion 2a located second fiber layer plant section 2 B at the fiber layer 2 at. In particular, the outer surface is located 27b of the intermediate part 27 at the fiber layer 2 at. Here, the outer surface forms 27b of the intermediate part 27 the outer surface 20a of the formation 20 ,

After providing the arrangement of the forming structure 20 and the surrounding fiber layer 2 in a manufacturing device 110 according to the 1 or the 2 , and vacuum is applied in an autoclave hardening of the matrix material in the fiber layer 2 is located or via the matrix material supply line 116 at the same time applied vacuum of the fiber layer 2 is supplied. By curing the matrix material in the fiber layer 2 becomes a component interior IR defining component wall 4 of the hollow profile component 1 educated. The component wall 4 has a matrix material layer 3 on top of that the fiber layer 2 contains.

The curing of the matrix material takes place in the closed manufacturing device 110 So if the arrangement of the forming structure 20 and the surrounding fiber layer 2 on or in the tool 11 located and from the vacuum film 112 surrounded or enclosed airtight. Preference is given to a complete curing of the matrix material, that is to say that the matrix material is in a solidified, non-plasticized state over the entire cross-sectional thickness. However, it can also be provided that only a partial hardening of the matrix material takes place so that the matrix material is still present in sections of the cross section, preferably in the interior thereof, in a plasticized state. In this procedure, the removal takes place at least the foam core part 22 in the plasticized state of the fibrous layer 2 , Alternatively, additional hardening may occur prior to removal of at least the foam core portion 22 respectively.

After the hardening phase, an annealing phase can still be provided, the temperature being lower in the injection phase than in the hardening phase.

The temperature profile and the vacuum control are provided such that in the cured component in the fiber layer 2 the same optimum quality, the smallest possible number of pores or air pockets and a suitable fiber volume fraction is achieved. The temperature or the temperature profile provided during curing depends in particular on the material of the matrix material.

When hardening can be provided in particular that the vacuum is maintained at a constant level. In particular, a pressure of e.g. 1 mbar to 10 mbar (absolute pressure) to be set. After curing, no vacuum is required.

In a manufacturing device 110 with matrix material supply line 116 after 1 the process temperature is set during curing such that in the case of a respectively used matrix material this has a low viscosity, so that the matrix material in the molding section 114 can flow in and in the fiber layer 2 distributed. Typical necessary viscosities during the phase of introduction of the matrix material are, for example, in a range between 1 and 1000 m Pa s. Typical temperatures are between 50 degrees C to 150 degrees C for the phase of inflow of the matrix material or injection phase and between 70 degrees C to 120 degrees C for the cure phase. For the optionally provided subsequent tempering phase temperatures between 50 degrees C to 130 degrees C can be set.

In a manufacturing device 110 without matrix material supply line 116 after 2 the process temperature is set during curing such that in the case of a respectively used matrix material this has a low viscosity, so that the matrix material in the fiber layer 2 is contained in the fiber layer 2 distributed. In this embodiment, typical necessary viscosities during the curing period are in a range of, for example, 1 to 1,000 m Pa s. Typical temperatures in the curing phase are between 50 degrees C to 180 degrees C and for the optional subsequent tempering phase between 50 degrees C to 130 degrees C.

After hardening of the matrix material, an intermediate Z is present, which consists of the hollow profile component which is in itself finished 1 and the forming structure located in the component interior IR thereof 20 is formed.

It can then be provided that the mold-tool device 10 is opened. This can be realized by using the vacuum film 112 from the first tool part 11 Will get removed.

The intermediate product is preferred for the following processing steps the tool part 11 taken. But it can also be provided that the further processing on the in the tool part 11 , eg a depression 11b the same intermediate product.

According to the invention, the hardening of the matrix material is followed by removal of at least the foam core part in all embodiments of the method 22 from the component interior IR.

Removing the foam core part 22 can in all embodiments by pulling the foam core part 22 made from the component interior IR. It can be provided that initially the foam core part 22 is pulled out and then the release film 23 from the component interior, for example, by subtracting them from the component wall 4 Will get removed.

It can also be provided that the removal of the foam core part 22 by simultaneous extraction of the foam core part 22 and the release film 23 takes place, as in the 4 is shown. This has the advantage of removing the foam core part 22 and the release film 23 can be done in one processing step. This improves the process in terms of time.

In the in the 1 to 6 shown embodiment of the method, the forming structure 20 be pulled out of the component interior IR in particular along the fiber layer longitudinal direction L2 or pushed out. This can be done, for example, by manually attacking a supernatant of the release film 23 respectively. Also, the pulling out or pressing can be realized, for example, that on an end face 22s the foam core part 22 a removal device (not shown) is attached and that for removing the forming structure 20 necessary force is applied via the removal device. For example, the removal device may have a contact portion and a holding portion. The contact portion may be formed as a helical portion which extends along the fiber layer elongation direction L2 at the end face 22s in the foam core part 22 is screwed in. Also, the contact portion may be formed as a vacuum suction cup, which at the end face 22s attached and with which a negative pressure can be generated, so that the vacuum suction cup on the end face 22s liable. Subsequently, a force in or against the fiber layer Längrichtung L2 can be applied to the removal device via the holding portion, for example manually or with a moving device, which on the foam core part 22 is transmitted through the contact section. This will form the formation 20 pulled or pushed out of the component interior IR.

In the in the 7 to 11 and 12 to 14 shown embodiments, due to the multi-part construction of the molding 20 with the molding core 21 and the mold core intermediate structure 24 For example, first of all the shaping inner core 21 preferably together with the release film 23 be pulled or pressed out of the component interior IR, for example in the manner described above by means of a removal device. Subsequently, the intermediate structure parts 24 . 25 and 26 is removed or, as will be described below, are removed abrasive or chemical. Instead of according to the 7 used manufacturing device with a matrix material supply line 116 For supplying matrix material into a forming space in which a fibrous layer is located, a manufacturing apparatus without a matrix material supply line may also be used 116 be provided. Because the release film 23 only very badly or not at all at the mold core intermediate structure 24 can stick out the pulling out of the molding inner core 21 done very quickly and without much effort. Thus, even with complex geometries of the hollow profile component 1 the forming structure 20 be removed in an effective manner from the component interior IR. This is a particularly lightweight hollow profile component 1 generated. Under certain circumstances, it may also be desirable parts of the mold core intermediate structure 24 , as in 14 shown to be left in the component interior IR.

As an alternative to pulling out or pressing, in all embodiments of the method, a removal of the foam core part 22 be carried out by abrasive removal with a gas-solid jet. As in the 5 . 10 . 13 and 16 is shown by means of a jet device 40 a multiphase fluid jet is guided into the component interior IR. The blasting device 40 For example, it may be formed as a nozzle to which a jet generating device (not shown), such as a pump, is connected. In particular, the fluid jet has a carrier gas, such as air, and solid particles, such as sand particles, plastic particles (acrylic) or metal particles or the like. To remove the foam core part 22 becomes the jet device 40 on the foam core part 22 directed and the jet generating device is activated, whereby the gas-solid jet generated and the foam core part 22 gets destroyed.

For abrasive removal of the foam core part 22 the solid particles bounce off the release film 23 back. In particular, these are due to the release film 23 elastic cushioned. As a result, the kinetic energy of the solid particles is not or only to a very small extent to the fiber layer 2 passed, causing damage to the fiber layer 2 through the release film 23 reliably and effectively prevented. The release film 23 in this case acts as a protective layer for the fiber layer 2 , A particularly reliable protection results in particular in the use of release films 23 , with the above-described properties in terms of extensibility, film thickness and material.

Another way to remove the foam core part 22 represents chemical dissolution of the same with a solvent. For this purpose, the solvent, for example, with a spray device to the foam core part 22 be sprayed. Also in this case forms the release film 23 a protective layer, because the release film 23 one of the foam core part 22 has different chemical solubility.

Generally, after removing the foam core part 22 the release film 23 and optionally the interlayer release film 29 . 31 . 33 be removed from the component interior IR. This can be done in particular by manually removing the release film 23 from the fiber layer 2 ( 5 ), the surrounding mold core intermediate structure 24 ( 10 ) or fiber layer 2 and mold core intermediate structures 24 ( 13 ) respectively. It can also be provided that the release film 23 after removing the foam core part 22 in the component Interior IR remains as in 17 shown. Removing release liner 23 and optionally the interlayer release film 29 . 31 . 33 from the component interior IR after removal of the foam core part 22 has the advantage that thereby possibly still adhering to the respective film material residues of the foam core part 22 or the intermediate parts 25 . 26 . 27 also be removed. Thus, especially in complex geometries such as undercuts of the component wall 4 of the hollow profile component 1 the forming structure 20 completely without residue from the component interior IR removed. As a result, the weight of the hollow profile component 1 reduced.

The 6 . 11 and 14 each show in produced by the process according to the invention hollow profile component 1 , This may in particular have a tubular cross-sectional shape. The hollow profile component 1 may be provided, for example, for use as a structural component in a motor vehicle.

LIST OF REFERENCE NUMBERS

 1

Hollow-profile component

 1a

Outer surface of the hollow profile component

 1b

Inner surface of the hollow profile component

 2

fiber layer

 2a

first fiber layer contact section

 2 B

second fiber layer contact section

 3

Matrix material layer

 4

component wall

 10

Mold device

 11

first tool part of the molding tool device

 11a

first tool contour surface

 112

vacuum film

 112a

Inner surface of the vacuum film 112

 112b

connecting portion

 112c

contact section

 113

molding space

 114

forming section

 15

mover

 116

Matrix material supply line

 17

Material-receiving portions

 20

forming structure

 20a

outer surface of the forming structure

 21

Shaping inner core

 22

Foam core part

 22a

Outer surface of the foam core part

 23

release film

 23a

Outer surface of the release film

 23b

Inner surface of the release film

 24

Mold core intermediate structure

 25, 26, 27

Between structure-part

 25a, 26a, 27a

Inner surface of the respective intermediate part

 27b

Outer surface of the intermediate part

 28, 30, 32

Between structure-core part

 29, 31, 33

Between structure-release film

 29b, 31b, 33b

Outer surfaces of the interlayer release films

 34, 35, 36

Foam core sections

 40

ray device

 IR

Component interior

 L2

Fiber layer longitudinal direction

 ML2

 Length of the first fiber layer contact section

 U2

Fiber layer circumferentially

 Z

intermediate

 ZR

gap

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 non-patent literature

• Standard ASTM D882 [0070]

Claims (17)

Method for producing a fiber-reinforced hollow profile component ( 1 ), the method comprising the following steps: - establishing negative pressure in a closed forming section ( 114 ) one through a vacuum film ( 112 ) limited forming space ( 113 ) in which a shaping structure ( 20 ), wherein the shaping section ( 114 ) between the forming structure ( 20 ) and the vacuum film ( 112 ) and in the forming section ( 114 ) a fibrous layer ( 2 ) located on the forming structure ( 20 ) extends adjacent in a fiber layer longitudinal direction (L2) and encloses this in a direction transverse to this fiber layer circumferential direction (U2), wherein the forming structure ( 20 ) a molding core ( 21 ), which consists of a foam core part ( 22 ) and one extending along the fiber layer longitudinal direction (L2) and the foam core part (FIG. 22 ) in the fiber layer circumferential direction (U2) at least partially enclosing and adjoining this release film ( 23 ) is formed, - by creation of negative pressure in the forming section ( 114 ) Introducing matrix material through a feed opening ( 118 ) in the shaping section ( 114 Hardening of the matrix material by applying temperature in a predetermined temperature range over a predetermined period of time and thereby forming a component wall defining a component interior (IR) ( 4 ) with a matrix material layer ( 3 ), which the fiber layer ( 2 ), - removing at least the foam core part ( 22 ) from the component interior (IR). Method according to claim 1, wherein the shaping structure ( 20 ) of the fiber layer ( 2 ) forming fibers umwebt, wrapped, braided. Method for producing a fiber-reinforced hollow profile component ( 1 ), the method comprising the following steps: - establishing negative pressure in a closed forming section ( 114 ) one through a vacuum film ( 112 ) limited forming space ( 113 ) in which a shaping structure ( 20 ), wherein the shaping section ( 114 ) between the forming structure ( 20 ) and the vacuum film ( 112 ) and in the forming section ( 114 ) a fiber layer formed from reinforcing fibers and matrix material ( 2 ) located on the forming structure ( 20 ) extends adjacent in a fiber layer longitudinal direction (L2) and encloses this in a direction transverse to this fiber layer circumferential direction (U2), wherein the forming structure ( 20 ) a molding core ( 21 ), which consists of a foam core part ( 22 ) and one extending along the fiber layer longitudinal direction (L2) and the foam core part (FIG. 22 ) in the fiber layer circumferential direction (U2) at least partially enclosing and adjoining this release film ( 23 ) is formed by applying temperature in a predetermined temperature range over a predetermined period curing of the matrix material and thereby forming a component interior (IR) defining Bauteilwandung ( 4 ) with a matrix material layer ( 3 ), which the fiber layer ( 2 ), - removing at least the foam core part ( 22 ) from the component interior (IR). Method according to claim 3, wherein the formation of negative pressure in the molding section ( 114 ) Matrix material through a feed opening ( 118 ) in the shaping section ( 114 ) is introduced. Method according to one of the preceding claims, wherein the release film ( 23 ) of the inner core ( 21 ) over its entire extent at the fiber layer ( 2 ) is present. Method according to one of claims 1 to 4, wherein the release film ( 23 ) of the inner core ( 21 ) over its entire extension from a mold core intermediate structure ( 24 ) surrounded between the release film ( 23 ) and the fiber layer ( 2 ) and is applied to these over their entire extent. Method according to one of claims 1 to 4, wherein the release film ( 23 ) in at least a first fibrous layer contact section ( 2a ) rests against the fiber layer and at least one mold core intermediate structure ( 24 ) in a respective one, with respect to the fiber layer longitudinal direction (L2), laterally of the first fiber layer abutment section (FIG. 2a ) located second fiber layer contact section ( 2 B ) at the fiber layer ( 2 ), wherein the mold core intermediate structure ( 24 ) between the release film ( 23 ) and the fiber layer ( 2 ) is arranged at this also fitting. Method according to one of the preceding claims, wherein the removal of the foam core part ( 22 ) by pulling it out of the component interior (IR) and then the release film ( 23 ) is removed from the component interior. Method according to one of claims 1 to 7, wherein the removal of the foam core part ( 22 ) by simultaneous extraction of the foam core part ( 22 ) and the release film ( 23 ) he follows. Method according to one of claims 1 to 7, wherein the removal of the foam core part ( 22 ) carried out by abrasive removal with a gas-solid jet. Method according to one of claims 1 to 7, wherein the removal of the foam core part ( 22 ) is carried out by chemical dissolution with a solvent. Method according to claim 10 or 11, wherein after removal of the foam core part ( 22 ) the release film ( 23 ) is removed from the component interior (IR). Method according to one of the preceding claims, wherein the shaping core ( 21 ) a foam core part composed of a plurality of foam core sections ( 22 ) having. Method according to one of claims 6 to 13, wherein the mandrel intermediate structure ( 24 ) of several intermediate parts ( 25 . 26 . 27 ) is formed. Method according to one of claims 6 to 14, wherein the mold core intermediate structure ( 24 ) from at least one intermediate core part ( 28 . 30 . 32 ) and one extending along the fiber layer longitudinal direction (L2) and the respective intermediate core part ( 28 . 30 . 32 ) in the fiber layer circumferential direction (U2) enclosing and adjoining this inter-film release film ( 29 . 31 . 33 ) is formed. Method according to one of the preceding claims, wherein one or more of the following components are formed from a rigid foam material: (a) the foam core part ( 22 ), (b) the intermediate structure ( 23 ). Method according to one of the preceding claims, wherein the release film ( 23 ) is made of or comprises one or more of the following materials: - copolymer material, - polyamide or polyamide mixtures, - polyolefins, - polyurethane, - teflon, - polyether block amides, - polyethylene terephthalate, - polyvinylchloride films, - nylon ,

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