DE102016206025A1 - Process for producing a pultruded fiber composite plastic profile - Google Patents

Abstract

In order to further improve a method for producing a pultruded fiber composite plastic profile in such a way that the fiber composite profile produced thereby can be subsequently formed, welded and sprayed back so that even complex component geometries can be produced, it is proposed that several strands of a fiber material be arranged next to one another and warmed up and then impregnated with a thermoplastic matrix material before being fed to the pultrusion tool for pultrusion.

Description

The invention relates to a method for producing a pultruded fiber composite plastic profile from a plurality of impregnated with a thermoplastic matrix material strands of a fiber material.

Furthermore, the invention relates to a pultruded fiber composite plastic profile and an apparatus for producing a pultruded fiber composite plastic profile.

Pultrusion is an economical manufacturing process for the continuous production of fiber-plastic composite profiles. The pultrusion process is also called pultrusion. In this case, the fiber material is impregnated or impregnated with a matrix material and then cured in a pultrusion tool. The matrix material reacts to the polymer. In the pultrusion tool, the fiber material impregnated with the matrix material is shaped.

Usually pultruded fiber composite plastic profiles are based on a thermosetting matrix, whereby the freedom of shaping is limited. The resulting profiles can not be subsequently or very difficult to reshape. Furthermore, such profiles are not recyclable, weldable and sprayable. As a result, the applications for complex shaped components are very limited.

State of the art

In the DE 10 2011 005 329 A1 For example, a continuous process for producing a fiber-reinforced composite plastic, in particular a tensile carrier, is described. For this purpose, several fibers are embedded in a polymer matrix and then pultruded.

DESCRIPTION OF THE INVENTION: Problem, Solution, Advantages

The object of the present invention is to further improve a method for producing a pultruded composite plastic profile in such a way that the resulting fiber composite plastic profile can be subsequently deformed, welded and sprayed in order to be able to produce components of complex shape.

• a) Zuführen mehrerer Stränge des Faserwerkstoffs in eine Aufwärm-Imprägniervorrichtung; und
• b) Anordnen der Stränge nebeneinander; und
• c) Aufwärmen der Stränge; und
• d) Imprägnieren der Stränge mit dem Matrixwerkstoff; und
• e) Zuführen der mit dem Matrixwerkstoff imprägnierten Stränge in ein Pultrusionswerkzeug, wobei die imprägnierten Stränge pultrudiert und zum Faserverbundkunststoff-Profil geformt werden.

According to the invention, a method for producing a pultruded fiber composite plastic profile from a plurality of strands of a fiber material impregnated with a thermoplastic matrix material is proposed for this purpose. The method according to the invention has at least the following steps:

• a) feeding a plurality of strands of the fiber material into a warm-up impregnating device; and
• b) arranging the strands side by side; and
• c) warming the strands; and
• d) impregnating the strands with the matrix material; and
• e) feeding the strands impregnated with the matrix material into a pultrusion die, wherein the impregnated strands are pultruded and formed into the fiber composite plastic profile.

The strands of the fiber material can be supplied for example in the form of continuous fiber rovings, but also as yarns, threads or other semi-finished textile product. Preferably, the fiber material comprises glass fibers. The matrix material is formed as a thermoplastic matrix material, preferably as a reactive thermoplastic matrix material, and forms the starting point for the thermoplastic material. The matrix material is preferably based on a lactam system, for example on caprolactam.

The abovementioned steps a) to e) of the process according to the invention are to be carried out according to the invention in the abovementioned sequence. Thus, the strands are arranged side by side before or during warming and only then impregnated with the matrix material. After impregnation, the impregnated strands are pultruded.

The individual strands of the fiber material can be unwound by means of a Faserzuführeinheit, for example by means of rollers or coils, and fed to the warm-up impregnating device. In the warm-up impregnating device, the fiber material or the individual strands of the fiber material are first warmed up and then impregnated with the matrix material, for example sprayed or doused. The aforementioned steps according to the invention are carried out in a continuous process sequence. All juxtaposed strands are passed through the warm-up impregnating device at the same time and at the same speed, for example pulled through. Before or during the warm-up, the strands are arranged side by side. This is to be understood that the individual strands are arranged essentially distributed on one level next to each other. Preferably, the individual strands are arranged on a substantially horizontally oriented plane.

In the pultrusion tool, the strands impregnated with the matrix material are eliminated Fiber material pultruded so that the matrix material reacts and polymerizes. Here, the fiber composite plastic profile is formed.

It is preferably provided that the impregnated strands of additional matrix material is supplied in the inlet region of the pultrusion tool. As a result, if necessary, the surface quality of the fiber composite plastic profile can be improved.

The fact that the strands are arranged side by side, all strands can be evenly impregnated or impregnated with the matrix material in a simple manner. This allows a very good impregnation of the individual strands. The air is already removed from the overall system before the strands of fiber material are fed to the pultrusion tool. As a result, a high quality without defects in fiber composite plastic profile can be achieved. As a result, a fiber composite plastic profile produced by the process according to the invention has very good mechanical properties or characteristic values, for example tensile strengths of more than 1200 MPa. Furthermore, fiber composite plastic profiles, produced by the method according to the invention, can be subsequently formed, welded and spray-coated, so that even complex component geometries are possible. The fiber composite plastic profiles can thus also be used in the automotive sector. Furthermore, the edge trimmings or waste are recyclable and can thus be better utilized.

Preferably, the fiber composite plastic profile is produced as a hollow profile. By this is meant that the resulting fiber composite plastic profile has a continuous and longitudinal cavity, which is circumferentially enclosed by the fiber composite plastic.

Furthermore, it is preferably provided that the impregnated strands are brought together by means of a merging device to form a contour close to the final fiber composite plastic profile before the impregnated strands are fed to the pultrusion tool. For this purpose, the strands arranged next to one another, particularly preferably substantially on one level, are first impregnated and then brought together in a geometry close to final contour in the desired fiber composite plastic profile. For this purpose, the impregnated strands are preferably aligned with the hollow profile.

The merging device may be formed, for example, as a perforated plate, wherein the strands are pulled through individual holes or openings. The holes or openings through the perforated plate can be arranged according to the desired profile shape in the perforated plate. For example, an impregnated strand or several impregnated strands can be pulled through each individual hole or through each individual opening. Furthermore, a tool part, for example the core, of the pultrusion tool can be arranged with the end face of this tool part on the merging device, in particular of the perforated plate, or connected thereto. As a result, the tool part, for example the core, of the pultrusion tool can be fixed. The impregnated strands are passed through the apertures or holes of the perforated plate (merging device) and distributed around the tool part (core) of the pultrusion tool circumferentially around and arranged distributed substantially uniformly.

Furthermore, it is preferably provided that the juxtaposed strands of the fiber material are impregnated by means of at least one impregnating device, wherein the impregnating device is alternately moved back and forth transversely to a withdrawal direction of the strands. For this purpose, the impregnation device is particularly preferably moved back and forth in the horizontal direction and transversely to the withdrawal direction of the strands. In this case, the molten or liquid matrix material can be uniformly applied to the juxtaposed fiber strands, for example, poured.

The strands of the fibrous material are preferably heated in a substantially closed space in heated air prior to impregnation within the warm-up impregnator. This is to be understood that the heated air is arranged in a substantially closed system. The closed space or the closed system may be completed by the housing of the warm-up impregnating device. Alternatively, a self-contained space could be formed within the warm-up impregnator. Also, a plurality of separate or separate substantially closed spaces could be provided within the warm-up impregnating device. The air is used to warm up the strands of the fiber material in the substantially closed space is most preferably at a temperature between 60 ° C and 160 ° C, and most preferably on a temperature between 80 ° C and 140 ° C, warmed up.

It is also preferable for the strands to be warmed and dried in at least two successive stages in the warm-up impregnating device. In a first stage, the strands arranged side by side can be guided or pulled over a heating plate. The heating plate is thereby preferably heated to a temperature between 120 ° C and 160 ° C, and particularly preferably to a temperature between 140 ° C and 150 ° C, heated.

In a second stage, the strands can be led around individual bolt-shaped heating elements, such as Walkbolzen. Particularly preferably, at least three mutually parallel and vertically offset bolt-shaped heating elements are provided. The bolt-shaped heating elements are particularly preferably heated to a temperature between 140 ° C and 180 ° C, and most preferably preferably to a temperature between 150 ° C and 170 ° C, heated. Furthermore, it is particularly preferably provided that the heating elements are heated in the second stage to a higher temperature than the heating element, for example, the heating plate, in the first stage. Thus, the first stage preferably serves as a preheat stage, wherein the strands preheated in the first stage are further heated and dried in the second stage.

Characterized in that the heating elements in the second stage are preferably arranged as bolt-shaped heating elements, for example as a Walkbolzen, and vertically offset from each other, the juxtaposed strands of the fiber material can be guided around the bolt-shaped heating elements such that thereby the sizing (coating) on the fiber strands is broken. This allows a better drying of the fiber material as well as a better subsequent impregnation of the strands can be achieved.

The two individual warm-up stages may preferably be separated from one another within the warm-up impregnating device by a perforated plate. Through the individual holes or openings in the perforated plate, the strands can be pulled through. Preferably, the holes or openings for this purpose are arranged on a plane or very particularly preferably on a substantially horizontally oriented plane.

Furthermore, it is preferably provided that the strands of the fiber material are warmed and / or impregnated in predried air before and / or during the impregnation within the warm-up impregnating device in a substantially closed space. In this case, the air in the substantially closed space in which the strands of the fiber material are heated and / or impregnated, up to a relative humidity of less than 10%, particularly preferably less than 5%, dehumidified or predried.

The strands are preferably spread within the warm-up impregnator prior to and / or during heating. The strands are arranged side by side and slightly spaced from each other and guided or pulled through the warm-up impregnating device. By spreading the individual strands they can be warmed up better and more effectively, dried and then impregnated.

According to the invention, a pultruded fiber composite plastic profile of a plurality of impregnated with a thermoplastic matrix material strands of a fiber material is further provided, wherein the pultruded fiber composite plastic profile was prepared by a method described above.

Preferably, the fiber material comprises or consists of glass fibers. The matrix material is preferably based on a lactam system, for example on caprolactam or laurolactam.

Furthermore, an apparatus for producing a previously described pultruded fiber composite plastic profile from a plurality of strands of a fiber material impregnated with a thermoplastic matrix material is provided according to the invention. For this purpose, the device has a warm-up impregnating device for heating and drying the strands and for impregnating the strands with the matrix material. The warm-up impregnating device is followed by a pultrusion tool, to which the strands impregnated or impregnated with the matrix material are fed for shaping. The device according to the invention is designed for producing a pultruded fiber composite plastic profile according to a method described above.

Preferably, the warm-up impregnating device is substantially closed, in particular circumferentially closed, formed. Also, at least one substantially closed space could be arranged within the warm-up impregnation device. Under the essentially closed-off warm-up Impregnating device is to be understood that within the warm-up impregnating at least one substantially closed space with warmed up and pre-dried air for heating and drying of the fibers is arranged from the fiber material. For supplying the individual strands of the fiber material, the warm-up impregnating device may have corresponding openings. Also, the warm-up impregnating device has at its exit a corresponding opening for passing through the impregnated strands and for feeding the impregnated strands into the downstream pultrusion tool. The pultrusion tool is thus preferably arranged outside the warm-up impregnation device. Additional matrix material can be introduced to improve the surface quality of the Pultrusionsprofils in the inlet region of the pultrusion tool.

Brief description of the drawings

The invention is explained below by way of example with reference to preferred embodiments.

They show schematically:

1 FIG. 2 is a schematic diagram of a device for producing fiber composite plastic profiles, FIG.

2 FIG. 1 shows a further basic illustration of an apparatus for producing fiber composite plastic profiles, FIG.

3a a merge device,

3b : a perforated plate, and

4 a pultrusion tool.

Preferred embodiment of the invention

In the 1 and 2 each is a schematic diagram of a device 200 for the production of fiber composite plastic profiles 100 shown. By means of one or more Faserzuführeinheiten 14 become single strands 12 of the fiber material 11 the warm-up impregnator 13 fed. So that the individual strands 12 within the warm-up impregnator 13 can be better warmed up, dried and impregnated, can spreaders 19 for spreading the individual strands 12 be provided.

Inside the warm-up impregnator 13 are diverters (in 1 not shown) for the deflection and alignment of the individual strands 12 intended. Furthermore, within the warm-up impregnator 13 perforated plates 20 provided, with the individual strands 12 through the openings or holes in the perforated plates 20 can be pulled through. The single strands 12 be in the departure direction 18 through the warm-up impregnator 13 pulled.

Between individual perforated plates 20 can the strands 12 warmed up or dried. Then the strands become 12 with the matrix material 10 impregnated or impregnated. For this purpose, the impregnation device 17 in the horizontal direction and transversely to the withdrawal direction 18 alternating back and forth.

After impregnation of the individual strands 12 become the impregnated strands 12 by means of a merging device 16 according to the desired profile, in particular a hollow profile aligned. In the process, the impregnated strands become 12 by means of the merging device 16 to a final composite fiber profile 100 Contoured geometry merged and then the pultrusion tool 15 fed.

In the inlet area of the pultrusion tool 15 can through a matrix feed 26 additional matrix material can be introduced.

In the pultrusion tool 15 become the impregnated strands 12 shaped, wherein the matrix material 10 reacts and polymerizes.

By means of in 1 shown device 200 can be a fiber composite plastic profile 100 be manufactured with hollow profiles.

In 2 is another schematic diagram of a device 200 for the production of fiber composite plastic profiles 200 shown. As in 2 can be shown, the warming or drying of the individual strands 12 be provided in individual successively arranged stages. For example, the strands 12 arranged side by side in a first stage and a hotplate 22 be guided. Subsequently, the preheated strands 12 through the openings or holes of a perforated plate 20 passed and fed to the second warming or drying stage. The second warm-up stage can, for example, comprise a plurality of, in particular three, bolt-shaped heating elements arranged parallel to one another and offset in the vertical direction relative to one another 23 exhibit. The preheated strands 12 are doing around the bolt-shaped heating elements 23 guided around and thereby further warmed up and dried. By passing around the bolt-shaped heating elements 23 and simultaneous warm-up will be the sizing on the individual strands 12 of the fiber material 11 broken up, so that the fiber material 11 dried better and then can be better impregnated.

After the multi-stage warming and drying of the individual strands 12 These are in turn through holes or openings in other perforated plates 20 passed. Between these two further perforated plates 20 can the dried strands 12 by means of an impregnating device 17 with the matrix material 10 impregnated or soaked.

Subsequently, the with the matrix material 10 impregnated strands 12 by means of a merging device 16 corresponding to the desired hollow profile of the fiber composite plastic profile 100 arranged. For this purpose, the merging device 16 also be designed as a perforated plate, wherein the individual holes or openings are arranged according to the desired profile.

A tool part 21 of the pultrusion tool 15 can with its frontal end to the merger 16 be fixed. Thus, the individual impregnated strands 12 in a simple manner through the holes or openings of the merging device 16 through and around the tool part 21 of the pultrusion tool 15 be arranged distributed around. The tool part 21 is a core, especially as a floating core, in the pultrusion tool 15 arranged or led into this.

In 3a is an exemplary embodiment of a merge device 16 shown. The merging device 16 may be formed as a perforated plate, wherein the individual holes or openings corresponding to the desired shape of the fiber composite plastic profile 100 (in 3a not shown) are arranged. In the individual holes or apertures collar nozzles, for example made of ceramic, which prevents the individual strands 12 (in 3a not shown) rub against each other and prematurely comes to filament breaks.

Furthermore, the in 3a shown merging device 16 central holes for fixing the tool part 21 at the pultrusion tool 15 (in 3a also not shown).

In 3b is an exemplary embodiment of a perforated plate 20 shown. The perforated plate 20 has a plurality of spaced apart and evenly spaced holes or openings. In the individual holes or apertures collar nozzles, for example made of ceramic, which prevents the individual strands 12 (in 3b not shown) rub against each other and prematurely comes to filament breaks.

4 shows a section of a pultrusion tool 15 with a first tool part 21 , The first tool part 21 is as a floating core in the pultrusion tool 15 arranged. At a front end, the tool part 21 several juxtaposed holes on. The holes serve as fixations 24 for fixing the tool part 21 at the merger device 16 (compare to this 3a ). Further holes are as holes 25 for heating elements, such as heating cartridges, formed, bringing the tool part 21 can be warmed up.

Thus, the tool part 21 with its front side outside the pultrusion tool 15 at the merger device 16 be fixed.

LIST OF REFERENCE NUMBERS

100

 FRP profile

200

 Apparatus for producing fiber composite plastic profiles

10

 Matrix material

11

 Fiber material

12

 Strands of the fiber material

13

 Warm-impregnation

14

 fiber feeding

15

 pultrusion

16

 Merge means

17

 impregnating

18

 withdrawal direction

19

 spreading

20

 perforated plates

21

 Tool part of the pultrusion tool

22

 heating plate

23

 heating elements

24

 fixations

25

 Holes for heating elements

26

 matrix feed

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 102011005329 A1 [0005]

Claims (11)

Process for producing a pultruded fiber composite plastic profile ( 100 ) of several with a thermoplastic matrix material ( 10 ) impregnated strands ( 12 ) of a fiber material ( 11 ), the method comprising at least the following steps: a) feeding a plurality of strands ( 12 ) of the fiber material ( 11 ) in a warm-up impregnation device ( 13 ); and b) arranging the strands ( 12 ) side by side; and c) warming up the strands ( 12 ); and d) impregnating the strands ( 12 ) with the matrix material ( 10 ); and e) feeding the with the matrix material ( 10 ) impregnated strands ( 12 ) into a pultrusion tool ( 15 ), the impregnated strands ( 12 ) pultruded and the fiber composite plastic profile ( 100 ) are formed. A method according to claim 1, characterized in that the fiber composite plastic profile ( 100 ) is produced as a hollow profile. Process according to claim 1 or 2, characterized in that the impregnated strands ( 12 ) by means of a merging device ( 16 ) to a final composite fiber profile ( 100 ) conformal geometry before the impregnated strands ( 12 ) the pultrusion tool ( 15 ). Method according to one of the preceding claims, characterized in that the strands ( 12 ) of the fiber material ( 12 ) by means of at least one impregnation device ( 17 ) are impregnated, wherein the impregnation device ( 17 ) transverse to a withdrawal direction ( 18 ) of strands ( 12 ) is alternately moved back and forth. Method according to one of the preceding claims, characterized in that the strands ( 12 ) of the fiber material ( 11 ) prior to impregnation within the warm-up impregnation device ( 13 ) are heated in a substantially closed room in heated air. Method according to claim 5, characterized in that the strands ( 12 ) are warmed and dried in at least two successive stages. Method according to one of the preceding claims, characterized in that the strands ( 12 ) of the fiber material ( 11 ) before and / or during the impregnation within the warm-up impregnating device ( 13 ) are warmed and / or impregnated in a substantially closed space in predried air. Method according to one of the preceding claims, characterized in that the strands ( 12 ) within the warm-up impregnation device ( 13 ) are spread before and / or during heating. Pultruded fiber composite plastic profile ( 100 ) of several with a thermoplastic matrix material ( 10 ) impregnated strands ( 12 ) of a fiber material ( 11 ), characterized in that the pultruded fiber composite plastic profile ( 100 ) was prepared by a method according to any one of the preceding claims. Contraption ( 200 ) for producing a pultruded fiber composite plastic profile ( 100 ) of several with a thermoplastic matrix material ( 10 ) impregnated strands ( 12 ) of a fiber material ( 11 ), the device ( 200 ) a warm-up impregnation device ( 13 ) to warm up the strands ( 12 ) and for impregnating the strands ( 12 ) with the matrix material ( 10 ), wherein the warm-up impregnating device ( 13 ) a pultrusion tool ( 15 ), which is connected to the matrix material ( 10 ) impregnated strands ( 12 ) are fed to the shaping, characterized in that the device ( 200 ) for producing a pultruded fiber composite plastic profile ( 100 ) is formed by a method according to claims 1 to 8. Contraption ( 200 ) according to claim 10, characterized in that the warm-up impregnating device ( 13 ) is substantially closed, in particular circumferentially closed, is formed or inside a closed space for warming up and / or impregnating the strands ( 12 ) having.

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