Component for absorbing energy and process for producing the component

Abstract

The present invention relates to a component for absorbing the energy of an impact applied to a component (19), the component (19) being plastically deformable by the impact and optionally capable of undergoing at least some fracture, the component (19) comprising a sheet profile (1) as a primary component and a foamed secondary component (17), the foamed secondary component (17) being connected to the sheet profile (1) and having a thermal conductivity of 0.2 g / cm 3 It has a density exceeding . The invention further relates to composite units (21) constructed from such components (17) and processes for producing the components (17).

Description

[Technical Field]

[0001] explanation The present invention relates to a component for absorbing energy from an impact applied to the component, the component comprising a sheet profile and a foamed secondary component.

[0002] Components for absorbing energy through deformation from an impact are used in, for example, automobile structures, and may be, for example, a bumper, an assembly part arranged between a lateral bumper member and the bumper, or an A-pillar, B-pillar, or C-pillar of a vehicle body, as well as a rocker area.

[0003] Energy-absorbing structures, also known as crash absorbers, are produced, for example, from molded foams based on polypropylene or polyurethane. A characteristic feature of the materials in these systems is their low modulus of elasticity under static or dynamic impact loads, resulting in large deformation distances.

[0004] In addition to crash absorbers made from polymer foams, crash absorbers made from metal or polymer structures are also known. These designs typically include ribs or honeycomb structures. However, a drawback of these crash absorbers is that they typically suffer sudden failure rather than uniform deformation when subjected to forces, such as those caused by an impact.

[0005] Also, seat profiles typically used on the A-, B- or C-pillars of a vehicle have the drawback that when subjected to a force, the force level drops suddenly and these seat profiles generally bend.

[0006] To optimize the force / displacement curve, a maximum of 0.2 g / cm from EP 2 404 788 A1 is used. 3It is known to provide a component for absorbing energy which comprises a core made from a polymer foam having a density of 0.15 to 0.5 mm.

[0007] A further component for absorbing energy is disclosed in WO 2017 / 137480, which comprises a primary structure and a secondary structure, the primary structure being made from a metal or continuous fiber reinforced polymer material, and the secondary structure being made from an unreinforced polymer material or a polymer material reinforced with short or long fibers.

[0008] If the crash absorber is to absorb a large amount of energy, the seat profile must have a design that allows it to absorb the desired amount of energy and does not completely fail before the desired amount of energy has been absorbed, which can result in a complex design of the seat profile or an undesirable thickness of the sheet used for the seat profile.

[0009] It is therefore an object of the present invention to provide a component for absorbing the energy of an impact applied to the component, which is of a less complex design and / or lighter weight than known crash absorbers for absorbing the same amount of energy.

[0010] This object is achieved by a component for absorbing the energy of an impact applied to the component, the component being plastically deformable by the impact and optionally capable of undergoing at least some degree of fracture, the component comprising a sheet profile as a main component and a foamed secondary component, the foamed secondary component being connected to the sheet profile and having a thermal conductivity of 0.2 g / cm 3 It has a density exceeding .

[0011] By connecting a foamed secondary component to the sheet profile, the energy absorption properties of the foam and the sheet profile are combined. Typically, when metal is used as the material for the sheet profile, the sheet profile absorbs energy by controlled bending of the profile. When a polymer is used as the material for the sheet profile, the energy is absorbed by controlled destruction of the material, for example by tearing or breaking of the fibers used to reinforce the polymer, or by tearing or breaking of the compound, if the polymer is unreinforced or if long or short fibers are used for reinforcement.

[0012] Foamed secondary components typically absorb energy by elastic deformation, however this only allows a relatively small amount of energy to be absorbed by the foam.

[0013] The components of the present invention combine the energy absorption types of a sheet profile and a foamed secondary component, which allows for a less complex design of the sheet profile and / or the use of a thinner sheet material than would be possible with a sheet profile having the same absorption properties without the foamed secondary component.

[0014] During an impact on the component, the seat profile, as the primary component, absorbs the majority of the energy. The energy absorption causes the seat profile to deform in a controlled manner. The foamed secondary component increases the amount of energy that the primary component can absorb, as the foamed component provides support and ensures correct deformation. This allows a component that includes a seat profile and a foamed secondary component to absorb a larger amount of energy than a seat component that does not include a foamed secondary component.

[0015] The material from which the seat profile is made can be any suitable material that can deform or break in a controlled manner upon impact with the component. Preferably, the seat profile is made from metal or polymer.

[0016] If the sheet profile is made from metal, any metal that deforms elastically or plastically on impact can be used, with steel, aluminum or aluminum-containing alloys being preferred.

[0017] If the seat profile is made from a polymer, it is preferred that the seat profile is made from polyamide (PA), polybutylene terephthalate (PBT), polystyrene (PS) or polypropylene (PP) or polyethylene (PE). Regardless of the type of polymer used for the seat profile, the polymer may be reinforced or unreinforced, with reinforced polymers being preferred.

[0018] Fibers are preferably used to reinforce polymers. Fibers suitable for reinforcing polymers can be, for example, short fibers, long fibers, continuous fibers, or a mixture of at least two of these. Fibers can be, for example, carbon fibers, glass fibers, aramid fibers, or mineral fibers. When continuous fibers are used for reinforcement, they can be used, for example, as woven fabrics, knitted fabrics, or in the form of rovings. Furthermore, continuous fibers can be arranged in parallel or layers, with the fibers in each layer arranged parallel, and the fibers of two adjacent layers can form any angle between them in the range of 10 to 90°.

[0019] The polymer may contain further additives to set the properties, such as dyes, plasticizers, stabilizers such as UV stabilizers, flame retardants, and any other additives known to those skilled in the art.

[0020] The foamed secondary component may be made from polymer foam or metal foam. When the foamed secondary component is made from polymer foam, the polymer foam used to produce the component has a density of at least 0.25 g / cm. 3 The polymer foam may be composed of any suitable polymer that allows for the production of a polymer foam having a density of 0.01 to 0.05 MPa. Preferably, the polymer foam is a polyamide foam, such as a polyamide foam based on polyamide 6, polyamide 6 / 6.36, polyamide 12, polyamide 610, polyamide 6 / 66, polyamide 6.12 or a copolyamide.

[0021] Preferably, the polyamide is a polyamide as described, for example, in WO 2020 / 016102 or a copolyamide as described, for example, in WO 2021 / 052881.

[0022] Thus, polyamides may be used, for example, (i) 15 to 84% by weight of at least one lactam; (ii) 16 to 85% by weight of a monomer mixture, (ii1) At least one C 32 -C 40 Dimer acid and (ii2) at least one C4-C 12 a monomer mixture comprising a diamine; and a polyamide produced by the polymerization of The monomer mixture contains 45 to 55 mol % of component (ii1) and 55 to 45 wt % of component (ii2) based on the total amount of the monomer mixture, and the sum of component (i) and component (ii) is 100 wt %.

[0023] When the polyamide is a copolyamide, the polyamide may be, for example, (A) 5 to 75 weight percent of at least one copolyamide prepared by polymerizing: (A1) 15 to 84% by weight of at least one lactam; (A2) A monomer mixture of 16 to 85% by weight, (M1) At least one C 32 -C 40 Dimer acid and (M2) At least one C4-C 12 a monomer mixture comprising a diamine; [the sum of components A1 and A2 is 100% by weight], and (B) 25 to 95% by weight of at least one polyamide different from the copolyamide (A) The polymer may be a polymer mixture comprising:

[0024] Polyamide (B) is polycaprolactam (PA6), polybutylene adipamide (PA4.6), polyhexamethylene adipamide (PA6.6), polyhexamethylene sebacamide (PA6.10), polyhexamethylene dodecane amide (PA6.12), poly-11-aminoundecanamide (PA11), polylaurolactam (PA12), poly-m-xylylene adipamide (PAMXD 6), polypentamethylene sebacamide (PA510), 6T / Z (Z = lactam), 6T / 6I / XY, 6T / XT (X = linear or branched C4-C 18 diamine), XT (X=C4-C 18 diamine), PA PACM 12 (PACM = p-diaminodicyclohexylmethane), PA MACM 12 (MACM = 3,3-dimethyl-p-diaminodicyclohexylmethane), PA MPMD 6 (MPMD = 2-methylpentamethylenediamine), PA MPMD T, PA MPMD 12, polyhexamethylene isophthalamide (PA 6I), polyhexamethylene isophthalamide-co-hexamethylene terephthalamide (PA6I / 6T), PA6-3-T (a mixture of terephthalic acid polyamide and 2,2,4- and 2,4,4-trimethylhexamethylenediamine), polybutylene sebacamide (PA 4.10), polydecamethylene sebacamide (PA 10.10), polypentamethylene adipamide (PA 5.6), PA6 / 66 and PA66 / 6, PA6Y (Y=C4-C 18 diacids) and their transamidation products.

[0025] When polymer foams are used to produce foamed secondary components, the polymers of the polymer foams may contain additives such as reinforcing additives, dyes, plasticizers, stabilizers, such as UV stabilizers and / or flame retardants, to achieve the intended density and set the properties of the polymer foam. When the polymers for the polymer foams contain reinforcing additives, these may be, for example, short fibers or powdered additives such as talcum. When short fibers are used, the fibers may be, for example, carbon fibers, glass fibers, aramid fibers, or mineral fibers.

[0026] To achieve the intended properties of the component, especially with regard to energy absorption, the foamed secondary component must have a density of at least 0.25 g / cm 3 Preferably, the foamed secondary component has a density of 0.25 to 0.45 g / cm 3 Density in the range of 0.3-0.4 g / cm 3 It has a density in the range of

[0027] The foamed secondary component can be made from open-cell or closed-cell foam. Furthermore, the foamed secondary component can also be made from a combination of open-cell and closed-cell foam, and can include open and closed cells. Furthermore, particularly when the foamed secondary component is made from a polymer foam, the foam can be a particulate foam or an open foam, with particulate foam being preferred.

[0028] Depending on the intended energy absorption properties, the foamed secondary component may be in at least partial contact with only one side of the seat profile, or may be in at least partial contact with both sides of the seat profile. If the foamed secondary component is in at least partial contact with both sides of the seat profile, it is even more preferred that the foamed secondary component is in contact with diametrically opposite sides of the seat profile.

[0029] To configure the energy absorption characteristics, it is further possible to use a sheet component having at least two sections with different geometries, such as different cross-sectional areas, different shapes, or different wall thicknesses. Varying the wall thickness is particularly preferred when using a cylindrical sheet component. In addition to using one sheet component with at least two sections, it is also possible to use at least two sheet components, each with a specific geometric shape. By varying the wall thickness, it is possible to configure the energy absorption characteristics to vary along the component, for example, by creating a gradient material that is softer at one end and harder at the other end.

[0030] The components can be used as a single component, or alternatively, at least two of the components are connected to form a composite unit. When at least two components are connected to form a composite unit, the seat profile of each component can have the same shape, or components with different seat profile shapes can be used. When the seat profiles have different shapes, at least two of the components can have seat profiles of the same size but different shapes. Alternatively or additionally, the components can have different sizes and the seat profiles of each component can have different lengths. In the latter case, the cross-sectional geometries of the seat profiles in the components of different lengths can be the same.

[0031] At least two components may be connected in parallel and / or in series. In this context, unless defined differently for a particular embodiment, "in parallel" means that the components are connected such that the longest central axes of the connected components are arranged in parallel, and "in series" means that the longest axes of the two connected components are arranged in series.

[0032] By connecting at least two components it is possible to optimize the energy absorption properties of the composite unit by using different shapes of the sheet profiles of the different components.

[0033] In particular, when extrusion profiles are used as seat profiles, it is preferable for the extrusion axis to be oriented in the direction of the force. If extrusion profiles with different lengths are used in the component, it is possible to create a desired force profile during an impact, with the shorter seat profile being more effective in the axial direction after the impact and contributing to energy absorption.

[0034] Alternatively, it is also possible to use sheet profiles with different wall thicknesses, in which case, in the direction of the impact, the impact preferably acts first on the component with the sheet profile with the lower wall thickness and then on the component with the sheet profile with the larger wall thickness.

[0035] When components are arranged in parallel and in series, it is further preferred that the parallel arranged components comprise seat profiles with corresponding shapes, and that the shapes of the seat profiles of the serially arranged components differ from those before and after in the direction of impact, where "parallel" and "series" relate to the direction of impact.

[0036] In addition to using components with differently shaped sheet profiles, it is also possible to adapt the properties of the foamed secondary components of the components used to form the composite unit, for example by varying the amount of additives, especially reinforcing additives, in the polymer foams of the different components.

[0037] To connect the components to form a composite unit, the components can be directly connected to each other, for example by gluing or welding. Alternatively or additionally, the components can be attached to tethers, which are preferably oriented transverse to the direction of impact.

[0038] The process for producing the component preferably comprises: (a) forming a sheet into a sheet profile; (b) connecting the sheet profile with a foamed secondary component.

[0039] To form the sheet profile, any process for forming a profile known to those skilled in the art can be used. If the sheet profile is made of metal or a thermoplastic polymer, it can be produced, for example, by a bending process, a deep drawing process, a pressing process, or an extrusion process. A combination of at least two of these forming processes to form the sheet profile is also possible. If the sheet profile is a hollow profile or a strand profile, the extrusion process is particularly preferred. The hollow profile or strand profile can be, for example, a tube profile or a polygonal profile, such as a triangular or quadrangular profile, or a polygon with five or more sides.

[0040] In particular, when producing sheet profiles in an extrusion process, it is possible to produce strand profiles with any suitable cross-sectional geometry.

[0041] After forming the sheet profile, the sheet profile is connected to the foamed secondary component. To this end, in one alternative, the foamed secondary component and the sheet profile can be formed in separate processes, followed by connecting the sheet profile and the foamed secondary component.

[0042] For the connection, the foamed secondary component can be attached to the sheet profile by any process known to those skilled in the art, for example by form-fit connection, force-fit connection or material-fit connection. Suitable connections between the sheet profile and the foamed secondary component are, for example, screw connections, rivet connections, adhesive bonds or clamps.

[0043] In addition to the above mentioned alternatives, it is further possible to connect the seat profile and the foamed secondary component by sliding the seat profile into the foamed secondary component.

[0044] When a sheet component is slid into a foamed secondary component, it is particularly preferred to use sheet components with different wall thicknesses or two or more sheet components, each with a specific wall thickness adapted to the desired energy absorption characteristics, in order to set the energy absorption characteristics. However, particularly when a sheet component is slid into a foamed secondary component for production purposes, it is preferred to use only one sheet component. In this case, it is particularly preferred that the shape of the sheet component remains the same and only the wall thickness is changed to set the failure characteristics.

[0045] In a further alternative, a sheet profile is formed and then placed in a mold to produce a foamed secondary component. In this case, after placing the sheet profile in the mold, a starting material for producing the foamed secondary component is fed into the mold, and the foamed secondary component is directly formed, partially or completely overmolding the sheet profile. If the foamed secondary component is made from an open-cell foam, it is preferable to feed a foam-forming reactant, including a blowing agent, to the foam and allow the foam to form in the mold. By this process, the foamed secondary component directly surrounds the sheet profile. If the foamed secondary component is made from a particle foam, expanded polymer beads are fed into the mold as a starting material, and after filling the mold with the expanded polymer beads, the expanded polymer beads are connected, thus forming a particle foam. To connect the expanded polymer beads, for example, steam is passed through the mold, and the steam has a temperature at which the polymer of the expanded polymer beads begins to melt so that the expanded polymer beads are welded together to form the particle foam.

[0046] Regardless of the type of connection between the sheet profile and the foamed secondary component and / or the component forming the composite unit, the primary structure and the secondary structure and / or the component of the composite unit are combined and support each other only under load. In this way, complex nonlinear force curves can also be generated through targeted interlocking of either the primary component or the foamed secondary component or the component of the composite unit on the deformation path.

[0047] The components or composite units can be used in automotive engineering, for example, as bumpers or as A-, B- or C-pillars, as well as in the side rocker area. Furthermore, the components or composite units can be inserted into vehicle components to strengthen them. The components and / or composite units can also be used in any other application where the energy of a possible impact should be at least partially absorbed.

[0048] Embodiments of the invention are illustrated in the drawings and are explained in more detail in the following description. [Brief explanation of the drawings]

[0049] [Figure 1a] 2 shows a cross-sectional view of the seat profile of FIG. 1 at the start of the impact. [Figure 1b] The sheet profile in Figure 1 is shown in the deformed state due to impact. [Figure 2a] 1 shows a component with a sheet profile according to the invention and a foamed secondary component. [Figure 2b] The components of Figure 3a are shown in their deformed state due to impact. [Figure 3a] Shows a single component. [Figure 3b] 1 shows the main spatial arrangement of components to form a composite unit. [Figure 4] 1 shows a component having an internal profile embedded within a foamed secondary component.

[0050] FIG. 1a shows a cross section of a sheet profile that can be used for the component.

[0051] The seat profile 1 may be formed as shown by way of example in Figure 1, comprising a base 3, a first leg 5 and a second leg 7, the first leg 5 terminating in a first edge 9 and the second leg 7 terminating in a second edge 11. In the design shown in Figure 1a, the first edge 9 and the second edge 11 are oriented parallel to the base 3.

[0052] The seat profile 1 is normally positioned so that an impact 13 acts on the base 3. The impact 13 is indicated by an arrow in Figure 1a. During the impact 13, the base is moved in the direction of the upper edge 15 of the seat profile 1, which upper edge 15 is formed by the first edge 9 and the second edge 11.

[0053] The impact 13 and the movement of the base 3 cause the first and second legs 5 and 7 to deform. Depending on the material of the seat profile 1, the first and second legs 5 and 7 may deform, for example, by buckling, as shown in Figure 1b. This occurs especially when the seat profile's material can deform elastically or plastically without breaking, such as when the material is a metal like steel. If the material tends to break upon impact, such as when the seat material is a thermosetting plastic material, especially a reinforced plastic material with continuous fibers, the legs 5 and 7 may begin to deform as shown in Figure 1b, but then break immediately. Depending on the thickness of the seat profile 1, deformation can occur even with a weak impact.

[0054] Furthermore, the energy that can be absorbed by the seat component 1 due to deformation of the seat component 1 is limited, especially if the seat profile has a relatively simple design, as shown for example in Figures 1a and 1b.

[0055] To increase the amount of energy that can be absorbed, according to the invention, the sheet profile 1 is connected with a foamed secondary component 17, thereby forming a component 19. Such a component is shown in cross section in Figure 2a and under impact load in Figure 2b.

[0056] The sheet profile 1 may be completely surrounded by the expanded secondary component 17 or, as shown here, only partially surrounded by the expanded secondary component 17. 3 The foamed secondary component 13, having a density of 17, supports the deformation of the seat profile 1 in such a way that an increased amount of energy can be absorbed by a controlled deformation of the seat profile 1. Furthermore, the foamed secondary component 17 allows the seat profile 1 to deform in a controlled manner by an impact 13 acting on the seat profile 1. This support of the deformation of the seat profile 1 and its deformation in a controlled manner allows it to absorb much more energy than the seat profile 1 alone.

[0057] 2a and 2b, if the seat profile 1 has legs 5, 7 that are deformed by an impact on the base 1, a foamed secondary component 17 is arranged on the surface of the legs. During the impact 13, the foamed secondary component 17 is compressed, thus absorbing part of the energy of the impact and supporting the seat profile 1 so that it assumes a deformation state more favorable for energy absorption under the load of the impact 13. In this way, the energy absorption properties of the seat profile 1 are improved by the employed foamed secondary component 17. Furthermore, the maximum load that indicates the onset of the failure range can be increased.

[0058] To optimize energy absorption properties, it is further preferred to combine at least two components 19 to form a composite unit 21. Exemplary components 19 are shown in Figure 3a, and the arrangement of components 19 to form composite unit 21 is shown in Figure 3b.

[0059] Each component 19 comprises a sheet profile 1 and a foamed secondary component 17. To form the composite unit 21, the components 19 may be combined in any suitable arrangement.

[0060] As shown in FIG. 3b, the components 19 can be arranged, for example, one above the other, side by side, and / or in series. The one-above-one and side-by-side arrangements can also be referred to as parallel arrangements. In this context, parallel arrangement can refer to the orientation of the main axis of the seat profile or, preferably, the expected direction of impact. Correspondingly, serial arrangement refers to components that are combined one after the other in the direction of the main axis of the seat profile or, preferably, in the expected direction of impact on the composite unit 21.

[0061] The arrangement of the components 19 may be such that the connecting sides of two adjacent components 19 are in contact over the entire surface area of ​​each side, however this is only feasible if all components 19 connected to form the composite unit 21 have the same size.

[0062] Alternatively, the components may be connected with an offset, regardless of whether all components 19 have the same size or whether at least some of the components 19 have different sizes.

[0063] If all components 19 have the same size as shown in Figure 3b, it is possible to include sheet profiles 1 with different geometries in components 19 in order to adapt the energy absorption characteristics to a particular failure behavior. On the other hand, it is also possible to connect components 19 that all have the same geometry, including the same geometry of sheet profiles 1, to form a composite unit 21.

[0064] Any suitable joining method known to those skilled in the art can be used to connect components 19 to form composite unit 21. Components can be connected, for example, with screws, rivets, adhesives, snap connections, or by attaching components 19 to tethers.

[0065] In addition to the geometric shape of the seat profile 1 shown in the figure, the seat profile may have any other geometric shape depending on the intended use of the component. The geometric shape of the seat profile can be determined, for example, by simulation calculations. Furthermore, the foamed secondary component 17 may completely or only partially surround the seat profile 1. If the foamed secondary component 17 only partially surrounds the seat profile 1, the surfaces of the foamed secondary component and the seat component may form the surface of the component 19, for example, as in the component of Figures 2a and 2b, where the base 3 and the surface of the foamed secondary component 17 form the bottom side of the component 19, and the edges 9 and 11 and the surface of the foamed secondary component 17 form the top side of the component 19. In addition to such an arrangement in which the seat profile 1 and the surface of the foamed secondary component 17 form the surface of the component 19, it is also possible for only a smaller portion of the seat profile 1 to be in contact with the foamed secondary component 17. In this case, the seat profile generally protrudes from the foamed secondary component 17.

[0066] If the sheet profile is a hollow profile, it is further possible for the foamed secondary component to be arranged only on the outer surface of the hollow profile, for the hollow profile to be only filled with the foamed secondary component, or for the foamed secondary component to be arranged inside the hollow profile and on the outer surface of the hollow profile.

[0067] Such a component 19 comprising a sheet profile 1 with a hollow profile in the form of a tube and a foamed secondary component 17 surrounding the sheet profile 1 on the outer surface of the hollow profile is shown in FIG.

[0068] If the sheet profile 1 is a hollow profile, such as a tubular hollow profile, the sheet profile 1 is arranged in the foamed secondary component 17 in such a way that the main direction of impact 13 corresponds to the main axis 23 of the hollow profile. The hollow profile is preferably produced by an extrusion process, so that the main axis 23 also corresponds to the extrusion direction.

[0069] After producing the hollow profile, the hollow profile is overmolded with the foamed secondary component 17. Alternatively, the hollow profile and the foamed secondary component 17 are produced separately, after which the hollow profile is slid into the foamed secondary component 17.

Claims

1. Component for absorbing the energy of an impact applied to a component (19), said component (19) being plastically deformable by the impact and optionally capable of undergoing at least some fracture, said component (19) comprising a sheet profile (1) as a main component and a foamed secondary component (17) connected to said sheet profile (1), said foamed secondary component (17) having a thermal conductivity of 0.2 g / cm ３ Components having a density greater than

2. Component according to claim 1, wherein the foamed secondary component (17) is made from a polymer foam.

3. The component of claim 2 , wherein the polymer foam is a polyamide foam.

4. 4. The component of claim 2 or 3, wherein the polymer foam is a particulate foam.

5. The polymer foam has a viscosity of 0.25 to 0.45 g / cm ３ 5. The component according to claim 1, having a density in the range of

6. 6. The component according to any one of claims 1 to 5, wherein the polymer foam is at least partially in contact with both sides of the seat of the seat profile (1).

7. 7. The component according to any one of claims 1 to 6, wherein the seat profile (1) is made from metal or polymer.

8. The component of claim 7 , wherein the metal is selected from the group consisting of steel, aluminum, and aluminum alloys.

9. 9. The component of claim 8, wherein the polymer from which the sheet is made is polyamide, polybutylene terephthalate, polystyrene, or polypropylene.

10. 10. The component of claim 7 or 9, wherein the polymer is reinforced.

11. A combined unit comprising at least two components (19) according to any one of claims 1 to 10, said components (19) being connected in parallel and / or in series.

12. 12. The composite unit of claim 11, further comprising a tether to which the component (19) is attached.

13. A process for producing a component according to any one of claims 1 to 10, comprising: (a) forming a sheet into the shape of said sheet profile (1); (b) connecting said sheet profile (1) with said foamed secondary component (17); The process includes:

14. 14. The process according to claim 13, wherein the foamed secondary component (17) and the sheet profile (1) are formed in separate processes, and the sheet profile (1) and the foamed secondary component (17) are subsequently connected.

15. 14. The process according to claim 13, wherein the sheet profile (1) is inserted into a mould, into which the starting material for forming the foamed secondary component (17) is subsequently fed.

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