METHOD FOR REINFORCEMENTING A BASIC STRUCTURE

Description

[0001] The present invention relates to a method for reinforcing an existing basic structure according to the preamble of claim 1, a process unit according to the preamble of claim 13 and a computer program according to claim 14.

[0002] Supporting structures comprise a base structure and a reinforcing structure. Flat base structures can be plates, discs, domes, or ellipsoids of revolution, for example. To achieve sufficient load-bearing capacity and rigidity of the base structures, the reinforcing structures, such as struts or rods, are first manufactured in a complex process. The struts and rods are then connected to the base structure to achieve sufficient load-bearing capacity and rigidity of the supporting structure as a combination of base structure and at least one reinforcing structure. However, this is complex and expensive. Furthermore, the reinforcing structures can only be adapted to different geometries of base structures with considerable effort.

[0003] US 2014 / 0061974 A1 discloses a method for producing a three-dimensional object from a composite material. Two or more materials are extruded simultaneously as a composite material.

[0004] US 2014 / 361460 A1 discloses a process in which a void-free reinforced filament containing a core, which may be continuous or semi-continuous, and a matrix material surrounding the core are prepared. The reinforced filament is heated to a temperature above the melting temperature of the matrix material and below the melting temperature of the core before the filament is extruded from an extrusion die.

[0005] WO 2015 / 009938 A1 discloses a device comprising a void-free reinforced filament comprising a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature above the melting temperature of the matrix material and below the melting temperature of the core before the filament is dispensed from a conduit nozzle.

[0006] DE 10 2011 109369 A1 discloses a method and a device for producing a three-dimensional object from solidifiable material. For this purpose, the solidifiable material is dispensed onto a slide for the three-dimensional object to be produced, with a continuous fiber element being fed into and embedded in the solidifiable material. The slide and a dispensing unit are movable relative to each other in space.

[0007] WO 2014 / 193505 A1 discloses a machine for producing a fiber-reinforced component by additive manufacturing. The machine comprises a matrix feeder that deposits a plurality of matrix layers on the surface, and a fiber feeder that deposits a fiber layer on at least one of the plurality of matrix layers. The deposition of the plurality of matrix layers and the fiber layer can be controlled by a computer.

[0008] EP 2 781 342 A1 discloses a method for manufacturing an article. Liquid matrix material is brought into contact with a fiber, and a coated fiber is extruded onto a substrate comprising a previously extruded coated fiber. The coating of the extruded fiber fuses with the previously extruded coated fiber and solidifies.

[0009] EP 2 676 784 A1 discloses a method for manufacturing an article, wherein a partially molten filament is extruded from the extrusion head onto a building board, wherein a reinforcement portion of the partially molten filament remains in a semi-crystalline state while being extruded from the extrusion head. A matrix portion of the extruded line solidifies after the extruded line has been formed on the substrate, wherein the reinforcement portion has a higher melting point and higher crystallinity than the matrix portion.

[0010] US 2005 / 0276945 A1 discloses a part made of a composite material and a method for manufacturing the part from the composite material. A first polymeric layer is bonded to a second polymeric layer, with at least one overhanging rib connecting the first and second polymeric layers.

[0011] DE 10 2014 006 706 A1 shows a method for producing a two-dimensional or three-dimensional framework with rods that are connected at nodes to at least one other rod and / or another component, from a composite material with fibers and a matrix, comprising the steps of: producing the rods from the composite material, connecting the rods at the nodes to at least one other rod and / or another component, wherein the rods are produced by pultrusion and / or extrusion and a pultrusion unit and / or an extrusion unit is moved in space, so that the pultruded and / or extruded rods are pultruded and / or extruded at the required position within the framework after the pultrusion and / or extrusion.

[0012] The object of the present invention is therefore to provide a method for reinforcing an existing basic structure with at least one reinforcing structure to form a supporting structure, a computer program and a computer program product, in which the basic structure can be reinforced with reinforcing structures inexpensively and reliably with little technical effort.

[0013] This object is achieved with a method according to claim 1. Also disclosed is a method for reinforcing an existing base structure with at least one reinforcing structure to form a supporting structure and / or with a method for producing a supporting structure with the steps: preferably providing or producing a base structure, producing the at least one reinforcing structure, connecting the at least one reinforcing structure to the base structure such that the at least one reinforcing structure is connected to the base structure in a connecting position and the base structure together with the at least one reinforcing structure forms the supporting structure, wherein the at least one reinforcing structure, in particular all of the reinforcing structures, is produced from a composite material with fibers and a matrix by means of pultrusion and / or extrusion.and a pultrusion unit and / or an extrusion unit is moved in space, so that the at least one reinforcement structure, in particular all of the reinforcement structures, is / are pultruded and / or extruded onto the base structure at the required connection position after the pultrusion and / or extrusion and is / are connected to the base structure by more than 50% of the length of the respective reinforcement structure, so that the length of the connection between the reinforcement structure and the base structure is greater than 50% of the length of the reinforcement structure. The reinforcement structures are pultruded and / or extruded at the required connection position on and / or at the base structure, so that after pultrusion and / or extrusion the at least one reinforcement structure no longer needs to be moved relative to the base structure.The costs for manufacturing the supporting structure can be significantly reduced because the at least one reinforcement structure is already manufactured at the connection positions where the at least one reinforcement structure is to be connected or fastened to the base structure. This advantageously eliminates the need for complex subsequent arrangement of already manufactured reinforcement structures at the required connection positions.

[0014] In a further embodiment, no movement is carried out with the pultruded and / or extruded at least one reinforcing structure, in particular all reinforcing structures, after pultrusion and / or extrusion and laying on the base structure, relative to the base structure and / or the matrix of the pultruded and / or extruded reinforcing structure, in particular all reinforcing structures, hardens at the required connection position on and / or on the base structure and / or the pultrusion and extrusion are carried out simultaneously and / or continuously.

[0015] In a further embodiment, for the production of the at least one reinforcement structure, pultrusion is carried out as a first step and extrusion is carried out as a second step, so that the pultruded at least one reinforcement structure partially produced in the first step, in particular all of the reinforcement structures, is / are post-processed by extrusion in the second step and / or the at least one reinforcement structure, preferably all of the reinforcement structures, is / are produced, in particular continuously, by the pultrusion unit and / or extrusion unit being moved, in particular continuously, in space in a movement path at and / or in the region of the required connection position at a distance from the base structure. The distance is small, in the range of a few mm or cm.The pultrusion unit and / or extrusion unit is essentially moved to the required connection position, since after the at least one reinforcement structure emerges from the process unit, the reinforcement structure still has a small distance from the base structure.

[0016] Advantageously, the at least one reinforcement structure is produced as a straight or curved rod and / or the movement path is substantially a straight line and / or, preferably, a curved line and / or the pultrusion unit and / or extrusion unit is moved by a robot and / or after pultrusion and / or extrusion of each reinforcement structure, the composite material with the bevels and the matrix is ​​separated by a cutting unit.

[0017] In a supplementary variant, at least one reinforcement structure is produced whose length is at least 2, 4, 5, 10 or 20 times greater than the diameter of this reinforcement structure and / or the cross-sectional shape of the at least one reinforcement structure, in particular of all reinforcement structures, is or are formed during extrusion and / or when placed on the base structure and / or the length of the reinforcement structure, in particular of all reinforcement structures, is or are formed by the length of the movement path of the pultrusion unit and / or extrusion unit and / or the at least one reinforcement structure, in particular all reinforcement structures, are produced without a cavity and / or without a hollow channel.When the at least one reinforcement structure is placed on the base structure, the composite material is not completely cooled and is therefore deformable, so that the composite material is adapted to the geometry of the base structure by deformation.

[0018] In a supplementary embodiment, the fibers and preferably the matrix are continuously conveyed first through the pultrusion unit and then through the extrusion unit and / or hybrid yarns with fibers and matrix are conveyed to the pultrusion unit or the fibers and the matrix are conveyed separately to the pultrusion unit and / or the fibers or the hybrid yarns are unwound from rolls and conveyed to the pultrusion unit and / or the at least one reinforcing structure, in particular all of the reinforcing structures, is / are produced such that at least one fiber, preferably a plurality of fibers, is / are arranged on an outer side of the at least one reinforcing structure, in particular all of the reinforcing structures, and / or the at least one reinforcing structure, in particular all of the reinforcing structures, is / are produced such thatso that at least one fiber, preferably a plurality of fibers, does / does not have a complete covering with the matrix and / or the at least one reinforcing structure, in particular all of the reinforcing structures, is / are produced such that the matrix is ​​arranged between the fibers. In the reinforcing structures, the fibers are firmly connected to one another by means of the matrix, since the matrix has hardened. The fibers are also arranged on the outside of the at least one reinforcing structure, so that the fibers are visible or tangible on the outside of the at least one reinforcing structure. In particular, the fibers are therefore not arranged in an inner region of the reinforcing structures and the matrix in an outer shell. Rather, the fibers and the matrix are distributed over the cross-sectional shape and the matrix is ​​also arranged between the fibers.Preferably, a reinforcing structure, in particular a rod, comprises, for example, at least two, three, five or ten fibers.

[0019] In an additional embodiment, the fibers are bonded to one another in a material-to-material ratio in the pultrusion unit during pultrusion by means of the matrix, in particular by heating and / or hardening the matrix and / or cooling and / or hardening the matrix during conveying from the pultrusion unit to the extrusion unit, so that the fibers are bonded to one another in a material-to-material ratio and / or the fibers and the matrix are conveyed by means of a conveying device, for example two conveying wheels, in particular by the conveying device acting on the fibers with the matrix during conveying the fibers with the matrix from the pultrusion unit to the extrusion unit and / or the fibers and the matrix are first bonded to one another in a material-to-material ratio by means of pultrusion, in particular by heating and / or hardening the matrix,are connected to one another and then, during extrusion in the extrusion unit, the cross-sectional shape of the at least one reinforcing structure is at least partially formed and / or the at least one reinforcing structure, in particular all reinforcing structures, is / are extruded with a maximum diameter between 1 mm and 30 mm, in particular between 2 mm and 20 mm.

[0020] In an additional embodiment, the fibers with the matrix are heated in the extrusion unit and / or the cross-sectional shape, preferably circular, elliptical or rectangular, of the at least one reinforcing structure is formed in the extrusion unit during extrusion and preferably due to the contact of the at least one reinforcing structure with the surface of the basic structure, the cross-sectional shape is formed again and / or the fibers with the matrix are first heated in the pultrusion unit, while the fibers with the matrix are conveyed from the pultrusion unit to the extrusion unit, the fibers cool down and are heated again in the extrusion unit of the fibers with the matrix and / or the fibers with the matrix are actively cooled in the pultrusion unit with a, preferably first, cooling device and / or the fibers with the matrix are cooled after conveying through the extrusion unit with a, preferably second,Cooling device, for example a fan, are actively cooled and / or the at least one reinforcement structure, in particular all reinforcement structures, are connected to the base structure by more than 70%, 80% or 90% of the length of the respective reinforcement structure, so that the length of the connection between the reinforcement structure and the base structure is greater than 70%, 80% or 90% of the length of the reinforcement structure.

[0021] In a further embodiment, the at least one reinforcement structure, in particular all of the reinforcement structures, is / are produced with plastic, preferably thermoplastic and / or thermosetting plastic and / or plastic as a reactive hotmelt or reactive hotmelt adhesive or reactive melt polymer, as the matrix and / or the at least one reinforcement structure, in particular all of the reinforcement structures, is / are produced with fibers as glass fibers, carbon fibers and / or aramid fibers and / or the at least one reinforcement structure, in particular all of the reinforcement structures, is / are produced exclusively from matrix and fibers and / or the at least one reinforcement structure, in particular all of the reinforcement structures, is / are producedsuch that the mass fraction or volume fraction of the fibers is at least 30%, 40%, 60% or 80% and / or the at least one reinforcing structure, in particular all of the reinforcing structures, is / are produced such that the mass fraction or volume fraction of the matrix is ​​less than 70%, 60%, 40% or 20% and / or the at least one reinforcing structure, in particular all of the reinforcing structures, is / are produced such that the at least one reinforcing structure is / are formed exclusively from the fibers and the matrix. Plastics as reactive hot melt or reactive hot melt adhesive or reactive melt polymer are plastics which preferably initially have thermoplastic properties and / or are a thermoplastic plastic, and after at least one change parameter, for example heating orHeating and / or exposure to moisture and / or irradiation with UV light and / or oxygen deprivation, through a chemical change, in particular at least one chemical reaction, have thermosetting properties and / or are a thermosetting plastic. If a change parameter of heating or warming is used, the heating and / or warming in the pultrusion unit and / or extrusion unit can be used as a change parameter and after the subsequent cooling and hardening of the matrix on the base structure, the support structure, in particular the reinforcement structure, has sufficient load-bearing capacity and / or rigidity even when heated or warmed. Thermosetting plastics are 100% solid even when heated or warmed, i.e. the hardening cannot be reversed by heating.The warming and / or heating in the pultrusion unit and / or extrusion unit is carried out at temperatures between 60°C and 200°C, for example. In the case of a reactive hot melt, for example based on polymers, the chemical change is brought about by a connection between existing macromolecular chains (so-called cross links). Reactive hot melts are, for example, based on EVA (ethylene vinyl acetate) and polyester, or on PA (polyamide), or on polymers, or on PUR. Reactive hot melts can also contain substances that are not plastics or adhesives. In this respect, adhesives are also considered plastics. An essential property of the reactive hot melt or reactive hot melt adhesive is that they have a high melting point and are therefore not particularly hot.reactive melt polymer is thus that after hardening due to the action of the at least one change parameter, heating of the at least one reinforcing structure does not cause melting of the reactive hot melt or the matrix from the reactive hot melt, so that despite heating to temperatures normal for the application, for example to temperatures up to 200° C or 300° C, the load-bearing capacity and / or rigidity of the supporting structure is still ensured.

[0022] In a further embodiment, the at least one reinforcement structure, in particular all reinforcement structures, is / are manufactured such that the length of the fibers, in particular all fibers, in each reinforcement structure substantially corresponds to the length of the at least one reinforcement structure and / or the at least one reinforcement structure, in particular all reinforcement structures, cool and harden on the surface of the base structure. "Substantially" means that the length of the reinforcement structure corresponds to the length of the fibers in the respective reinforcement structure with a deviation of less than 30%, 20%, 10%, or 5%.

[0023] According to the invention, before the at least one reinforcement structure is placed on the surface of the base structure, the material of the base structure is removed locally on the surface of the base structure in the region of a later contact surface between the at least one reinforcement structure and the base structure.

[0024] Preferably, the basic structure is removed by machining, in particular with a tool, preferably a milling tool, and the tool is moved by a robot along the surface of the basic structure.

[0025] In an additional variant, a preferably elongated recess is machined into the base structure due to the removal of the material of the base structure and the at least one reinforcing structure is subsequently introduced into the recess so that a positive connection between the at least one reinforcing structure and the base structure is formed at the recess, in particular after the cooling and hardening of the matrix.

[0026] In a supplementary embodiment, before the at least one reinforcement structure is placed on the surface of the base structure, the surface of the base structure is heated locally in the region of a later contact surface between the at least one reinforcement structure and the base structure with a base structure heating device, in particular a laser or an infrared radiator.

[0027] In a further embodiment, the basic structure heating device is moved by a robot along the surface of the basic structure and / or due to the heating of the surface of the basic structure, the material of the basic structure changes its property locally in the region of a later contact surface between the at least one reinforcing structure and the basic structure, in particular becoming viscous and / or sticky and / or liquid, so that a material-to-material connection is formed between the matrix of the at least one reinforcing structure and the material of the basic structure, in particular after cooling.

[0028] In a supplementary embodiment, before the at least one reinforcing structure is placed on the surface of the base structure, a substance, in particular an adhesive and / or an adhesion promoter, is applied locally in the region of a later contact surface between the at least one reinforcing structure and the base structure using an addition device to improve the connection between the at least one reinforcing structure and the base structure.

[0029] Preferably, the adding device is moved by a robot along the surface of the base structure.

[0030] In a supplementary embodiment, the basic structure is first manufactured or provided and then the at least one reinforcement structure is manufactured.

[0031] Advantageously, the basic structure is produced using a different process than the at least one reinforcement structure.

[0032] The basic structure is expediently made of metal, in particular steel and / or aluminum, and / or of plastic, in particular fiber-reinforced plastic, and / or in a sandwich construction made of two different materials.

[0033] In a further variant, the basic structure is designed as a flat component, a plate, a disc, a partial spherical shell, a dome, a partial ellipsoid of revolution, a tub or a cup.

[0034] In an additional embodiment, the basic structure and / or the supporting structure is a load-bearing component, for example a beam, a column, a strut, a flange, a dome, a plate, a disc, a partial spherical shell, a wall or a ceiling, for a wide variety of applications, in particular in mechanical engineering, construction or electrical engineering.

[0035] In a supplementary embodiment, the at least one reinforcing structure is connected to a flat and / or curved surface of the base structure, preferably by producing the at least one reinforcing structure by means of extrusion and / or pultrusion on and / or on the flat and / or curved surface of the base structure.

[0036] In an expedient embodiment, the at least one reinforcement structure, preferably all reinforcement structures, is formed with plastic, preferably thermoplastic plastic and / or thermosetting plastic and / or plastic as a reactive hotmelt or reactive hotmelt adhesive or reactive melt polymer, as a matrix and / or the at least one reinforcement structure, preferably all reinforcement structures, are formed with fibers as glass fibers, carbon fibers and / or aramid fibers and / or the at least one reinforcement structure, preferably all reinforcement structures, is or are formed exclusively from fibers and matrix and / or the mass fraction or volume fraction of the fibers in the at least one reinforcement structure, preferably all reinforcement structures, is at least 30%, 40%, 60% or 80% and / or the mass fraction or volume fraction of the matrix in the at least one reinforcement structure,preferably all reinforcement structures, is less than 70%, 60%, 40% or 20% and / or the at least one reinforcement structure, preferably all reinforcement structures, are formed exclusively from the fibers and the matrix and / or the at least one reinforcement structure, preferably all reinforcement structures, are straight and / or curved and / or the length of the at least one reinforcement structure, preferably all reinforcement structures, is at least 2, 4, 5, 10 or 20 times greater than the diameter of the at least one reinforcement structure, preferably all reinforcement structures, and / or the at least one reinforcement structure, preferably all reinforcement structures, are formed without a cavity and / or on the at least one reinforcement structure, preferably all reinforcement structures,at least one fiber is arranged on the outside, or preferably several fibers are arranged, so that preferably the at least one fiber, preferably the several fibers, on the outside of the at least one reinforcing structure, preferably all reinforcing structures, is or are visible and / or tangible and / or at least one fiber, preferably several fibers, on the at least one reinforcing structure, preferably all reinforcing structures, does or do not have a complete covering with the matrix and / or the fibers are integrally connected to one another with the matrix arranged between the fibers.

[0037] The invention further comprises a processing unit according to claim 13 and a computer program according to claim 14 having program code means stored on a computer-readable data carrier for carrying out a method described in this patent application when the computer program is executed on a computer or a corresponding computing unit.

[0038] The disclosure also includes a computer program product having program code means stored on a computer-readable data carrier for carrying out a method described in this patent application when the computer program is executed on a computer or a corresponding computing unit.

[0039] In the following, embodiments of the invention are described in more detail with reference to the accompanying drawings.

[0040] It shows: Fig. 1 a simplified longitudinal section of a process unit with a pultrusion unit and extrusion unit for carrying out the process, Fig. 2 a side view of the process unit during the implementation of the process, Fig. 3 a cross section of a basic structure before the application of a reinforcement structure, Fig. 4 the cross section of the basic structure according to Fig. 3 after applying the reinforcement structure, Fig. 5 a cross section of basic structures and reinforcement structures in a first embodiment, Fig. 6 the cross section of basic structures and reinforcement structures in a second embodiment, Fig. 7 a plan view of a basic structure and reinforcement structures in a third embodiment, Fig. 8 a perspective view of the basic structure with reinforcement structures according to Fig. 7 , Fig. 9 a plan view of a basic structure and reinforcing structures in a fourth embodiment, Fig. 10 a perspective view of the basic structure with reinforcing structures according to Fig. 9 , Fig. 11 a plan view of a basic structure and reinforcing structures in a fifth embodiment, Fig. 12 a perspective view of the basic structure with reinforcing structures according to Fig. 11 , Fig. 13 a side view of a basic structure and reinforcing structures in a sixth embodiment, Fig. 14 a perspective view of the basic structure with reinforcing structures according to Fig. 13 .

[0041] In Fig. 1 and 2a process unit 5 for producing a reinforcement structure 1 is shown. The process unit 5 comprises a pultrusion unit 6 and an extrusion unit 7. In the pultrusion unit 6, a pultrusion channel 9 is formed and in a direction from right to left as shown in Fig. 1 The pultrusion channel 9 initially has a conically tapered section and then a section with a constant diameter. On the pultrusion channel 9 in the section with the constant diameter, a pressure is applied in a direction as shown in Fig. 1 from right to left and in a conveying direction of hybrid yarns 21 or of the reinforcement structure 1 to be produced or produced, first a first heating device 8 is arranged and then a first cooling device 10. A cooling channel 11 is formed on the first cooling device 10, through which a cooling fluid is passed to cool the partially produced reinforcement structure 1. The extrusion unit 7 comprises an extrusion channel 15 and the extrusion channel 15 comprises a first conically tapered section and a second section with a constant diameter. A second heating device 16 is formed on the second section of the extrusion channel 15 with the constant diameter. The first and second heating devices 8, 16 are preferably designed as an electrical resistance heater.In the conveying direction of the reinforcement structure 1 to be produced through the extrusion channel 15, the conically tapered section of the extrusion channel 15 is formed first, followed by the section of the extrusion channel 15 with the constant diameter. A conveyor device 12 is formed between the pultrusion unit 6 and the extrusion unit 7. The conveyor device 12 comprises a first conveyor wheel 13 and a second conveyor wheel 14, which are driven by an electric motor (not shown). The partially manufactured reinforcement structure 1 is arranged between the two conveyor wheels 13, 14, so that the partially manufactured reinforcement structure 1 is pulled out of the pultrusion unit 6 by the conveyor device 12 and pushed into the extrusion unit 7 by the conveyor device 12.

[0042] The pultrusion unit 6 and the extrusion unit 7 are provided with a connecting part 20, for example a Fig. 1 only partially shown housing. Furthermore, a feed part 23 with three guide bores 24 is attached to the connecting part 20. A hybrid yarn 21 is wound on each of three rolls 22. The hybrid yarn 21 consists of a fiber as a glass fiber and further comprises the matrix made of a thermoplastic. The matrix as the thermoplastic is arranged in the hybrid yarn 21 as a fibrous matrix or as a matrix fiber. The hybrid yarn 21 is flexible and can thus be unwound from the roll 22. Furthermore, a second cooling unit 17 is attached to the extrusion unit 7. The second cooling unit 17 comprises a blower 18 and a cooling pipe 19. By means of the blower 18, ambient air is guided through the cooling pipe 19, specifically to the area of ​​the reinforcement structure 1 immediately after leaving the extrusion unit 7.A cutting unit 25 serves to cut off the reinforcement structure 1 extruded on the extrusion unit 7 as required and thereby to produce an end of the reinforcement structure 1.

[0043] During the manufacture of the reinforcement structure 1 from the composite material 29 with the fibers and the matrix, the composite material 29 is prepared as shown in Fig. 1 first through the pultrusion unit 6 and then through the extrusion unit 7 by means of the conveyor device 12, however, both processes take place simultaneously due to the length of the rods 2 and the distance between the pultrusion unit 6 and the extrusion unit 7. During the conveying of the composite material 29, the hybrid yarn 21 is thus unwound from the three rollers 22 and introduced into the conically tapered section of the pultrusion channel 9. At the second section of the pultrusion channel 9 with the constant diameter, the three hybrid yarns 21 are heated with the first heating device 8 so that the thermoplastic of the matrix melts at the hybrid yarns 21 and thereby the glass fibers in the three hybrid yarns 21 are firmly bonded to one another by means of the matrix made of the thermoplastic as a pultrusion process.Subsequently, the composite material 29 with the fibers and the matrix is ​​conveyed or moved to the section of the pultrusion channel 9 with the first cooling device 10, so that the composite material 29 with the glass fibers and the thermoplastic is cooled and thereby hardened. After the composite material 29 emerges from the fibers and the matrix, the composite material 29 with the matrix is ​​conveyed or guided from the already partially manufactured reinforcement structure 1 by the conveyor device 12 into the extrusion unit 7. Due to the cooling of the composite material 29 with the fibers in the first cooling device 10, the composite material 29 with the fibers can be conveyed by the conveyor device 12.In the extrusion unit 7, the composite material 29 with the fibers and the matrix is ​​slightly heated again by the second heating device 16 at the section of the extrusion channel 15 with the constant diameter, to such an extent that the final shaping of the cross-sectional shape of the reinforcement structure 1 to be produced is formed at the end region in the conveying direction of the extrusion channel 15. The in . Fig. 1 The left end of the extrusion channel 15 has a circular cross-sectional shape, so that reinforcement structures 1 with a circular cross-section are produced by the process unit 5. After the reinforcement structures 1 exit the extrusion channel 15 of the extrusion unit 7, ambient air is directed as cooling air to the rod 2 by the blower 18 through the cooling pipe 19, so that a faster cooling of the reinforcement structures 1 can be achieved.

[0044] The reinforcement structures 1 produced by the method are designed as straight or curved bars 2. The bars 2 are produced by the process unit 5 at the required connection position on a base structure 4, so that the process unit 5 on a movement path 26 as a straight line 27 or curved line 27 by means of movement arms 28 of a Fig. 2 The movement path 26 as a straight line 27 or curved line 27 essentially corresponds to the longitudinal axis of the reinforcement structure 1 produced by the process unit 5. After the production of the bars 2 and the placement of the bars 2 or the reinforcement structures 1 on the surface of the base structure 4, no relative movement of the produced bars 2 to other bars 2 already produced or still to be produced or to the base structure 2 is required, since the bars 2 are already produced by the process unit 5 at the required connection position on the base structure 4. As a result, the costs for the production of a support structure 3 with the base structure 4 and reinforcement structures 1 by means of the process unit 5 can be significantly reduced. Fig. 2 The rollers 22 and the hybrid yarns 21 are not shown. The reinforcement structure 1 consists of rods 2 made of the composite material 29, namely with fibers as glass fibers and the matrix as a thermoplastic material.

[0045] In a further, not shown embodiment of the process unit 5, the fibers, e.g. glass, aramid or carbon fibers, are wound on the rollers 22 and the matrix as the thermoplastic plastic is stored separately in a container with a container heater in a heated state and conveyed to the pultrusion unit 6 by means of a matrix conveyor device (not shown). The pultrusion unit 6 and the extrusion unit 7 can also be designed as just one component, for example by carrying out the extrusion, i.e. the final shaping of an outer side 33 of the rod 2, immediately after the pultrusion, without the conveyor device 12 being arranged between the extrusion unit 7 and the pultrusion unit 6.

[0046] In a further embodiment not shown, instead of thermoplastic as the matrix, a thermosetting plastic or a plastic as a reactive hot melt or reactive hot melt adhesive or reactive melt polymer is used. The thermosetting plastic is stored separately in a container and fed to the extrusion unit 7 and / or the pultrusion unit 6 by means of a matrix conveyor. The thermosetting plastic is hardened by means of irradiation or the addition of chemical additives. The hardening of the plastic as a reactive hot melt or reactive hot melt adhesive or reactive melt polymer is carried out in particular by heating as a change parameter during processing of the matrix in the pultrusion unit 6 and / or in the extrusion unit 7.As an alternative, the plastic can also be cured as a reactive hot melt by moisture and / or UV light and / or oxygen deprivation. When curing by UV light, after the at least one reinforcement structure 1 has been placed on the base structure 4, the at least one reinforcement structure 1 is irradiated with UV light using a UV light source (not shown).

[0047] Pre-processing devices 34, 36, 38 as a tool 34 as a milling tool 35, a basic structure heating device 36, for example a laser 37 or an infrared radiator 38, and an addition device 39 for adhesive 31 are attached to the process unit 5 (only in Fig. 2 shown). The tool 34, the base structure heating device 36 and the addition device 39 are movable relative to the process unit 5 by mechanical means, so that the pre-processing devices 34, 36, 38 can be arranged in the required position on different movement paths 26 with different surfaces of base structures 4. Before placing the reinforcement structure 1 produced on the process unit 5 onto the surface of the base structure 4, an elongated recess 32 ( Fig. 3 ) with any cross-sectional shape, depending on the geometry of the milling tool 35, are milled into the base structure 4. The recesses 32 have an undercut, so that after cooling and hardening of the composite material 29 with the fibers and the matrix within the recess 32, a positive connection of the rods 2 as a reinforcement structure 1 on the base structure 1, for example plates 30, is formed.

[0048] Subsequently, the surface of the base structure 4 in the region of the recess 32 is heated with the base structure heating device 36 so that the matrix of the composite material 29 can bond to the material of the base structure 4 and, after cooling and hardening of the composite material 29 and the base structure 4, a firm bond exists between the base structure 4 and the reinforcement structure 1.

[0049] Adhesive 31 is then applied to the surface of the base structure 4 in the region of the recess 32 using the addition device 39 in order to firmly bond the reinforcement structure 1 to the base structure 4 after the reinforcement structure 1 has been placed on the base structure 4 and the adhesive 31 has hardened. In general, depending on the material of the base structure 4, only the base structure heating device 36 or only the addition device 39 is operated. If the base structure 4 is made of metal, for example steel or aluminum, only the addition device 39 and not the base structure heating device 36 is operated. If the base structure 4 is made of thermoplastic, only the addition device 39 and not the base structure heating device 36 is operated.

[0050] In Fig. 5 A cross section of basic structures 4 and reinforcing structures 1 is shown in a first exemplary embodiment. The basic structures 4 have a straight surface, and the basic structures 4 and reinforcing structures 1 are formed in layers one above the other. For example, a layer of the basic structure 4 is produced using a 3D printer, and then the reinforcing structure 1 is produced using the processing unit 5. The rods 2 can also be formed without a distance a between two adjacent rods 2 in a direction perpendicular to the plane of the drawing. Fig. 5 be extruded onto the surface of the base structure 4, so that the reinforcement structure 1 can also have a disc-shaped geometry.

[0051] In Fig. 6 A cross-section of base structures 4 and reinforcement structures 1 is shown in a second exemplary embodiment. The base structures 4 have a curved surface, and the base structures 4 and reinforcement structures 1 are formed in layers one above the other, so that the reinforcement structures 1 are also curved.

[0052] In Fig. 7 is a plan view of the basic structure 4 and reinforcement structures 1 and in Fig. 8 a perspective view of the base structure 4 with reinforcing structures 1 in a third embodiment. The base structure 4 has a straight surface, so that the reinforcing structures 1 are also straight. The reinforcing structures 1 have parallel to the plane of the drawing of Fig. 7 a distance a. The rod-shaped reinforcement structures 1 have a length L as the longitudinal extension in a longitudinal axis of the reinforcement structures 1.

[0053] In Fig. 9 is a plan view of the basic structure 4 and reinforcement structures 1 and in Fig. 10 a perspective view of the base structure 4 with reinforcing structures 1 in a fourth embodiment. The base structure 4 has a straight surface, so that the reinforcing structures 1 are also straight. The reinforcing structures 1 have parallel to the plane of the drawing of Fig. 9 a distance a.

[0054] In Fig. 11 is a plan view of the basic structure 4 and reinforcement structures 1 and in Fig. 12 a perspective view of the base structure 4 with reinforcing structures 1 in a fifth embodiment. The base structure 4 has a straight surface, so that the reinforcing structures 1 are also straight. The reinforcing structures 1 have parallel to the plane of the drawing of Fig. 7 a distance a, and furthermore, individual extruded rods 2 are materially joined to one another without a distance a by moving the process unit 5 along a corresponding movement path 26. To materially join the rods 2, they are extruded in such a way that the matrix has not yet cooled and / or the already extruded rods 2 are heated for the materially bonded connection.

[0055] In Fig. 13 is a side view of the basic structure 4 and reinforcement structures 1 and in Fig. 14 A perspective view of the base structure 4 with reinforcing structures 1 in a sixth exemplary embodiment is shown. The base structure 4 has a curved surface, so that the reinforcing structures 1 are also curved. The reinforcing structures 1 are partially arranged in recesses 32 of the base structure 4.

[0056] Overall, the method according to the invention for reinforcing the basic structure 4 offers significant advantages. The reinforcing structures 1 are produced from the composite material 29 with fibers and a matrix. During production, the process unit 5 is moved along a longitudinal axis of the reinforcing structure 1 to be produced, in particular the rod 2, as a straight or curved movement path 26, so that the rods 2 can be produced from the composite material 29 at the required connection position already on the surface of the basic structure 4 and the costs for producing the supporting structure 3 are thereby significantly reduced. When using the hybrid yarn 21, the proportion of the matrix and the fibers in the rods 2 is constant. By using a different number of hybrid yarns 21 orFibers for producing a rod 2, it is also possible to produce rods 2 with different diameters. Furthermore, the rods 2 can also be produced with different cross-sectional shapes. For this purpose, the end of the extrusion channel 15 has a . Fig. 1not shown, so that bars 2 can be easily manufactured not only as circular shapes but also as elliptical bars 2 or rectangular bars 2 in cross-sectional shape. The adaptation of the reinforcement structures 1 to base structures 4 with a wide variety of geometries can be achieved simply and inexpensively by the robot simply moving the process unit 5 along an adapted movement path 26. For this purpose, the robot either has sensors for detecting the geometry of the base structure 4 and / or the geometry of the base structure 4 is stored in a computing unit of the robot. Based on the data on the geometry of the base structure 4, the computing unit can calculate the movement path 26 for a given position for the at least one reinforcement structure 1.The adaptation of the geometry of the at least one reinforcement structure 1 to the geometry of the basic structure 4 can thus be carried out exclusively by programming and / or data technology, because any desired movement paths 26 in space can be carried out with the robot.

Claims

1. A method for reinforcing an existing base structure (4) with at least one reinforcing structure (1) to form a supporting structure (3), comprising the steps of: - providing or manufacturing the at least one reinforcing structure (1), - connecting the at least one reinforcing structure (1) to the base structure (4), so that the at least one reinforcing structure (1) is connected to the base structure (4) in a connection position and the base structure (4) together with the at least one reinforcing structure (1) forms the support structure (3), wherein the at least one reinforcing structure (1), in particular all reinforcing structures (1), is or are produced from a composite material (29) with fibres and a matrix by means of pultrusion and / or extrusion and a pultrusion unit (6) and / or an extrusion unit (7) is or are moved in space, so that the at least one reinforcing structure (1), in particular all reinforcing structures (1), is or are pultruded and / or extruded onto the base structure (4) in each case at the required connection position after the pultrusion and / or extrusion, characterised in that before the at least one reinforcing structure (1) is placed on the surface of the base structure (4), the material of the base structure (4) is removed locally on the surface of the base structure (4) in the region of a later contact surface between the at least one reinforcing structure (1) and the base structure (4).

2. The method according to claim 1, characterised in that no movement relative to the base structure (4) is or are carried out with the pultruded and / or extruded at least one reinforcing structure (1), in particular all reinforcing structures (1), after pultrusion and / or extrusion and placement on the base structure (4) and / or the matrix of the pultruded and / or extruded reinforcing structure (1), in particular all reinforcing structures (1), hardens at the required connection position on and / or to the base structure (4) and / or the pultrusion and extrusion are carried out simultaneously and / or continuously.

3. The method according to claim 1 or 2, characterised in that the at least one reinforcing structure (1), preferably all reinforcing structures (1), are or will be produced, in particular continuously, by moving the pultrusion unit (6) and / or extrusion unit (7), in particular continuously, in space in a movement path (26) at the required connection position at a distance from the base structure (4).

4. The method according to one or more of the preceding claims, characterised in that the at least one reinforcing structure (1) is produced as a straight or curved rod (2).

5. The method according to one or more of the preceding claims, characterised in that the cross-sectional shape of the at least one reinforcing structure (1), in particular of all reinforcing structures (1), is or are formed during extrusion and / or during placement on the base structure (4) and / or the length of the reinforcing structure (1), in particular of all reinforcing structures (1), is or are formed by the length of the movement path (26) of the pultrusion unit (6) and / or extrusion unit (7).

6. The method according to one or more of the preceding claims, characterised in that the fibres and preferably the matrix are continuously conveyed first through the pultrusion unit (6) and then through the extrusion unit (7).

7. The method according to one or more of the preceding claims, characterised in that the at least one reinforcing structure (1), in particular all reinforcing structures (1), is or are produced from a composite material (29) with fibres and a matrix by means of pultrusion and / or extrusion, and a pultrusion unit (6) and / or an extrusion unit (7) is or are moved in space so that, with respect to the length of the respective reinforcing structure (1) more than 50%, 70%, 80%, or 90% of the length of the respective reinforcing structure (1) is connected to the base structure (4), so that the length of the connection between the reinforcing structure (1) and the base structure (4) is greater than 50%, 70%, 80% or 90% of the length of the reinforcing structure (1).

8. The method according to claim 1, characterised in that the base structure (4) is removed by machining, in particular with a tool (34), preferably a milling tool (35), and the tool (34) is moved along the surface of the base structure (4) by a robot.

9. The method according to claim 1 to 8, characterised in that a, preferably elongated, recess (32) is machined into the base structure (4) as a result of the removal of the material of the base structure (4) and the at least one reinforcing structure (1) is then introduced into the recess (32), so that a positive connection is formed between the at least one reinforcing structure (1) and the base structure (4) at the recess (32), in particular after the matrix has cooled and hardened.

10. The method according to one or more of the preceding claims, characterised in that before the at least one reinforcing structure (1) is placed on the surface of the base structure (4), the surface of the base structure (4) is heated locally in the region of a later contact surface between the at least one reinforcing structure (1) and the base structure (4) using a base structure heating device (36), in particular a laser (37) or an infrared radiator (38).

11. The method according to claim 10, characterised in that the base structure heating device (36) is moved along the surface of the base structure (4) by a robot and / or due to the heating of the surface of the base structure (4) locally in the region of a later contact surface between the at least one reinforcing structure (1) and the base structure (4), the material of the base structure changes its property, in particular becomes viscous and / or sticky and / or liquid, so that a material-locking bond is formed between the matrix of the at least one reinforcing structure (1) and the material of the base structure (4), in particular after cooling.

12. The method according to one or more of the preceding claims, characterised in that before the at least one reinforcing structure (1) is placed on the surface of the base structure (4), a substance, in particular an adhesive and / or an adhesion promoter, is applied locally in the region of a later contact surface between the at least one reinforcing structure (1) and the base structure (4) using an additive device (39) in order to improve the bond between the at least one reinforcing structure (1) and the base structure (4).

13. A processing unit (5) adapted to be moved by a robot with moving arms (28) and adapted to perform the method according to any one of claims 1-12, comprising - a pultrusion unit (6) having a pultrusion channel (9) which has a first section followed by a second section in the conveying direction, wherein a first heating device (8) followed by a first cooling device (10) are arranged in the second section, - an extrusion unit (7) with an extrusion channel (15) which has a first section followed by a second section in the conveying direction, a second heating device (16) being formed on the second section, - a conveying device (12), which is arranged between the pultrusion unit (6) and the extrusion unit (7), for conveying the composite material (29) from the pultrusion unit (6) into the extrusion unit (7), characterised by - a milling tool (35) for removing the base structure (4) by machining.

14. A computer program comprising program code means for carrying out a method according to one or more of the claims 1 to 12, when the computer program is carried out on a computer connected to a process unit (5) according to claim 13.