Continuous production of profiles in a sandwich type of construction with foam cores and rigid-foam-filled profile

Patent metadata

Field	Value
Publication number	US-2016288431-A1
Application number	US-201415032927-A
Country	US
Kind code	A1
Filing date	Oct 22, 2014
Priority date	Oct 30, 2013
Publication date	Oct 6, 2016
Grant date	—

Abstract

The present invention relates to a novel process for the production of novel fibre-reinforced profile materials comprising a rigid foam core, in particular a PMI foam core. In particular, the present invention relates to a novel process which can be carried out in two variants, a short Pul-press process and a Pul-shape process. One step here produces a fibre-reinforced profile material and simultaneously inserts the rigid foam core into same. The same step moreover ensures very good binding of the rigid foam core to the fibre-reinforced profile material.

First claim

1 . A process for continuous production of fibre-reinforced profiles comprising a foam core, the process comprising:
a) introducing foam cores and connecting a newly introduced foam core to an end of the most recently introduced foam core; b) wrapping a fibre material around the foam core; c) impregnating the fibre-material wrap with a resin; d) optional optionally moulding the wrapped foam core in a first mould; e) heating and thereby optionally hardening the resin in a second mould; f) cooling the wrapped foam core in a third mould; and g) separating individual profiles by cutting or sawing and removing the finished workpiece, wherein the second and third mould are moved in respectively mutually opposite direction on carriages.

2 . The process according to claim 1 , wherein the foam core takes the form of a plurality of successive individual pieces when it is continuously passed into the pultrusion plant, and the individual pieces are connected to one another by adhesion bonding or insertion or through addition of a coupling piece.

3 . The process according to claim 1 , wherein the fibre material is carbon fibres, glass fibres, polymer fibres, or textile fibres.

4 . The process according to claim 1 , wherein the resin is a thermoset.

5 . The process according to claim 1 , wherein the fibre material is in the form of individual fibres, rovings, non-wovens, woven fabrics and/or laid scrims.

6 . The process according to claim 1 , wherein the foam core is a core comprising poly(meth)acrylimide.

7 . The process according to claim 6 , wherein polymethacrylimide in the density range from 30 to 200 kg/m 3 is used as material for the foam core.

8 . The process according to claim 1 , wherein b) takes place by analogy with a pultrusion process with foam core introduction in the form of a modified pul-preforming, pul-winding or pul-braiding process.

9 . The process according to claim 1 , wherein the process is conducted as Pul-press process in which a) to g) take place in moulds or, respectively, devices that are separate from one another.

10 . The process according to claim 1 , wherein the process is carried out as Pul-shape process in which the first and the second mould are the same mould, in which c), d) and e) are carried out simultaneously.

11 . A hollow profile comprising a foam core and of an outer material, wherein the outer material is a thermoplastic or thermoset reinforced with fibre material and the foam core is a rigid foam, wherein the profile comprising the rigid foam has no adhesive layer and no joins, and the outer material encloses the foam core entirely or with only very small gaps.

12 . The hollow profile according to claim 11 , wherein the rigid foam core has, at the interface between rigid foam core and jacket material, open pores comprising matrix material.

13 . The hollow profile according to claim 11 , wherein the outer material is a thermoset reinforced with a fibre material, the thermoset is a hardened epoxy resin or hardened PU resin, and the fibre material is carbon fibres or glass fibres.

14 . The hollow profile according to claim 11 , wherein the rigid foam is a PMI foam.

15 . An automobile construction, commercial vehicle construction, shipbuilding, aircraft construction, or helicopter construction, comprising the hollow profile according to claim 11 as a sandwich component, in the construction of installations suitable for obtaining energy from wind, in robotics or in aerospace technology.

16 . The process according to claim 1 , wherein the fibre material is aramid fibres.

17 . The process according to claim 1 , wherein the resin is a thermoset comprising a material comprising a polyester resin, a vinyl ester resin, a phenolic resin, a PU resin, an epoxy resin, or any combination thereof.

18 . The process according to claim 1 , wherein the resin is a thermoset comprising a material comprising a PU resin or an epoxy resin.

Assignees

• Bühler Sebastian
• Semlitsch Karl-Heinz
• Krishnamoorthy Sivakumara K
• Evonik Roehm Gmbh

Inventors

• Buehler Sebastian
• Semlitsch Karl-Heinz
• Krishnamoorthy Sivakumara K

Classifications

• B29K2477/00

  Use of {PA, i.e.} polyamides, e.g. polyesteramides {or derivatives thereof }, as filler · CPC title

• B29C70/224

  the structure being a net (B29C70/688 takes precedence) · CPC title

• B29C69/001

  a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts (for reinforced material B29C70/545; B29C49/4278, B29C51/268 take precedence) · CPC title

• B29L2022/00

  Hollow articles (tubular articles B29L2023/00; pneumatic tyres B29L2030/00) · CPC title

• B29K2033/00

  Use of polymers of unsaturated acids or derivatives thereof as moulding material {(B29K2035/00 takes precedence)} · CPC title