Method for manufacturing a composite profile section, profile section obtained and frame using such a profile section

Abstract

A profile section comprises at least one chamber (70), the chamber (70) being delimited by at least one shell. Each shell comprises two edges (751, 761) and is formed by a reinforcing material in the form of a textile web impregnated with a matrix made of synthetic material, each edge (751, 761) being superimposed on another of the edges (751, 761) in a region of overlap, the shell(s) around the chamber (70) forming a tube (71). Frame (9) produced with such profile sections and method for manufacturing the profile section.

Description

manufacturing process for a composite profile, resulting profile, and frame using such a profile

[0001] The invention relates to a method for manufacturing a composite profile of the type comprising a reinforcing material embedded in a synthetic matrix and a profile obtained by this method. It also relates to a frame manufactured using such a profile.

[0002] In the field of manufacturing photovoltaic or thermal solar panels, it is common practice to create a frame surrounding a glass plate which serves as a support for the cells or as a pane of glass to obtain a greenhouse effect.

[0003] A common technique for making frames involves using profiles with a tubular section topped by a groove. The groove is designed to hold the glass panel, which then rests against the tubular section. These profiles are typically made of aluminum alloy or composite material.

[0004] Document EP 4 258 542 A1 shows an example of such a profile made of composite material using a pultrusion process. The profiles are mitered to form a frame with brackets inserted into the tubular sections. The profile incorporates thin layers of textile on its surface for reinforcement and to facilitate the attachment of the brackets. These thin layers correspond to a traditional pultrusion technique for strengthening the transverse strength of the profiles. These layers are fed into the pultrusion tooling along with longitudinal fiber strands. The joining of the layers when a roll is exhausted creates a discontinuity in the profile that may need to be eliminated, generating significant stresses during production. Furthermore, joining the textiles is a delicate manual step that presents a significant risk of process interruption.

[0005] The assembly of the brackets and profiles uses nails, which induces mechanical stresses within the profiles and tends to weaken them by creating longitudinal cracks along the fibers. Furthermore, such profiles are made of thermosetting resin, making the recyclability of panels made with them problematic.

[0006] Document EP 867 270 B1 describes the manufacture of composite profiles based on glass fabric coated with a thermoplastic resin such as PVC. The fabric sheet passes through a die into which molten thermoplastic resin is injected. Although such a profile can have a homogeneous distribution of strength between the transverse and longitudinal directions, its range of applications is relatively limited because it is not feasible to produce fabric thicknesses at which the molten material would not be able to impregnate the central fibers.

[0007] One objective of the invention is therefore to provide a manufacturing process for profiles that are recyclable and usable, in particular, for the manufacture of photovoltaic or thermal solar panels. Another objective is to avoid production interruptions.

[0008] With these objectives in mind, the invention relates to a method for manufacturing a continuous composite profile, the profile comprising at least one chamber and consisting of a reinforcing material included in a synthetic matrix, a method in which at least one sheet of textile forming the reinforcing material of a shell is supplied to a tool in which the sheets are introduced and shaped, and in which the synthetic material is intimately bonded to the sheet or sheets, the chamber is delimited by at least one sheet, each sheet having two edges, each edge being superimposed on another edge in an overlap zone, and the synthetic material is hardened in the tool so that the sheets form the shells, the shell or shells around the chamber forming a tube, characterized in that the reinforcing material in the profile is derived from the sheets at least 50% by volume and represents at least 50% of the volume of the profile.

[0009] The production process allows for the continuous manufacturing of a profile, using sheets that form the shells after impregnation with the synthetic material. The use of highly reinforced shells results in a hollow profile with unprecedented mechanical properties. The synthetic material can be sourced from various sources, as detailed below.

[0010] According to an improvement, the textile web(s) are manufactured by an assembly unit directly upstream of the tooling. By forming the textile webs directly upstream of the tooling, continuous, uninterrupted production is possible. This eliminates the need for joining discontinuous strips. Indeed, the most frequent joins involve overlapping textiles to create an assembly with a seam. Such overlapping is very delicate with webs that fill most of the tooling's clearances, and their joining can create jams. Furthermore, the effort of winding and unwinding the webs is eliminated. It also prevents singular points or irregularities in the profile that would require cutting to remove them, thus avoiding stress and material loss.

[0011] In one embodiment, the synthetic material is supplied to the tooling in a fluid state as a reactive mixture. The process is a pultrusion process, and the tooling is a polymerization unit for achieving hardening by polymerization of the reactive mixture into a composite material matrix. The polymerization of a resin takes place in situ within the pultrusion tooling. A polymerization unit incorporates an impregnation zone followed by a polymerization zone shaped like the desired profile, so that the profile exits the polymerization unit in its final form, generally in a solid state. The polymerization zone thus also serves as a calibration zone. However, it may not perform this function, which is carried out by a dedicated calibration unit located separately downstream of the polymerization unit.

[0012] According to an improvement, the synthetic material after polymerization is a thermoplastic. The profile can exit the polymerization unit at a temperature below the melting point or glass transition temperature of its constituent matrix. It can also exit at a higher temperature, in which case a calibration and cooling die is provided for the tooling downstream of the polymerization zone. This die allows the synthetic material to harden and gives the profile its final cross-section.

[0013] As an example, the reactive mixture produces a synthetic material selected from a group including polyamides and polymethyl methacrylate. The advantage of this technology lies in the use of precursors such as very low-viscosity monomers, which allows for very high reinforcement ratios while achieving excellent and highly homogeneous fiber impregnation. Existing reactive systems for pultrusion are primarily based on anionic polymerization mechanisms of monomers, such as polyamide 6 from ε-caprolactam, polyamide 12 from lauryllactam, and polyamide 11, or on radical polymerizations, such as PMMA from methyl methacrylate.

[0014] In another embodiment, the synthetic material is thermoplastic material incorporated beforehand in the form of yarns or powder during textile manufacturing, prior to the shaping of the web(s). This material can thus be melted before or during processing in the tooling, so that the molten material is as close as possible to the fibers to be coated. It could also be supplied in the form of strips, called "tapes," mixing continuous unidirectional fibers and the thermoplastic material before the strips are assembled.

[0015] According to an improvement, the assembly unit forms non-interlaced, multi-axial reinforcing textiles. The production speeds of such an assembly and of pultrusion are of the same order of magnitude, namely approximately one to two meters per minute. Document WO 98 / 10128 A1 shows an example of a manufacturing process for such a textile.

[0016] According to one variant, the assembly unit is a weaving unit that forms fabrics. The fabric production speeds are also of the same order of magnitude as those of pultrusion.

[0017] According to an improvement, the assembly unit forms the textile with variations in thickness depending on its position in the width. This allows for the optimization of thicknesses according to the desired mechanical characteristics.

[0018] According to an improvement, at least one drive layer formed by longitudinal fibers is provided around the periphery of the plies to facilitate plies insertion and feeding into the tooling. Such a cover layer remains marginal in proportion to the volume of reinforcing material, with, for example, a thickness of less than 0.2 mm, or even 0.1 mm. It helps prevent, in particular, the retention of transverse fibers during plies passage through the tooling.

[0019] According to an improvement, a co-extrusion process is performed at the tooling exit to coat the profile with a layer of a second thermoplastic material. This external layer allows for the addition of specific characteristics to the profile. For example, this layer can provide a specific color or appearance, UV resistance, specific fire behavior, or moisture resistance. The second thermoplastic material is chosen to match the thermoplastic material of the matrix in order to achieve excellent bonding between the pultruded part and the layer. This bond is satisfactory when the second thermoplastic material is of the same type as the thermoplastic material of the matrix, for example, polyamide on polyamide, or polymethyl methacrylate on polymethyl methacrylate.In the case of a polyamide matrix, thermoplastic materials of different types can also be used by adding a treatment that promotes chemical compatibility with the polyamide, notably by grafting maleic acid into polypropylene (PP), polyethylene (HDPE), or polyvinylidene fluoride (PVDF). Polymer blends containing at least some polyamide, which bonds with the polyamide of the composite, can also be used.

[0020] The invention also relates to a profile comprising at least one chamber, wherein the chamber is delimited by at least one shell, each shell having two edges and being formed from a reinforcing material in the form of a textile web impregnated with a synthetic matrix, each edge being overlapped by another edge in an overlapping zone, the shell(s) around the chamber forming a tube, the reinforcing material being derived from the webs at least 50% by volume and representing at least 50% of the volume of the profile. Such a profile can be obtained directly by the process as described above.

[0021] The use of reinforcing textile layers allows for the creation of profiles with particularly advantageous mechanical properties. Compared to profiles produced by conventional pultrusion, where the reinforcing fibers are placed parallel to each other along the longitudinal axis of the profile, fibers can be inserted in a transverse direction, thus eliminating a source of weakness in previous profiles. The layers are not simply a superficial or marginal reinforcement of the profile, but rather constitute the complete framework of the shells, and the shells form the core of the profile's structure. Overlapping the edges of the layers prevents discontinuities in the profile's reinforcement and avoids weakening the profile.The choice of ply construction allows for optimization of the profile's strength, particularly through the distribution of textile fibers between the longitudinal and transverse or oblique directions. This type of reinforcement is especially advantageous when the profile is subjected to screws, nails, or punctures. If necessary, two or more plies can be overlapped across their entire surface to form a shell. The tubular shape of the profile allows for optimization of its mechanical properties relative to its mass, particularly its resistance to torsion and bending. All types of fibers commonly used as composite reinforcement can be used for the textile fibers, such as glass, carbon, aramid, or natural fibers like hemp or flax.

[0022] Preferably, the reinforcing material is derived from the layers at least 60% by volume.

[0023] In one embodiment, the chamber is defined by the inner faces of two shells, each edge of each shell being connected to one edge of the other shell by direct contact along an extension of the inner faces. The joined portion of the shells is achieved without the insertion of reinforcing material, with a junction that can be wide to ensure good adhesion between the shells. The textile layers extend over the entire surface of the junction, ensuring the cohesion of the shell and thus of the junction between the shells.

[0024] In one embodiment, the textile is a multi-axial non-interlaced reinforcement textile. In this type of textile, the warp and weft yarns are not interlaced, but rather superimposed in two or more layers. The entire structure is connected by stitching or knitting lines. The yarns can be oriented along a longitudinal direction, a transverse direction perpendicular to the longitudinal direction, or any oblique direction. Thus, the yarns are always positioned in a straight line within the textile, allowing them to be subjected to stress efficiently. When the yarns are interlaced, the tension on the yarn tends to eliminate the undulations, thereby reducing the apparent stiffness. A textile can be manufactured by increasing the number of layers to obtain the desired textile thickness, and therefore the intended profile strength. Document FR 2 993 284 A1 shows examples of such textiles.The thread used for the stitching is designed to maintain the overall consistency during the textile handling phases. However, the thread's density and strength can be increased to contribute to the overall strength of the finished product, particularly by reducing the risk of the layers separating under stress. In this case, the same type of thread used for the stitching can be employed. When manufacturing the profile requires multiple layers, these can be produced, if necessary, in parallel on the same machine, thus optimizing production speed.

[0025] In another embodiment, the tablecloth textile is a fabric. Different types of weave can be used depending on the desired mechanical properties, including three-dimensional weaving.

[0026] According to one improvement, the textile has variations in thickness depending on its position across its width. The thickness of the web is not necessarily constant across its width, but can be reinforced in certain areas as needed. To reinforce these areas, one can, for example, add a higher density of longitudinal fibers by locally increasing the number of warp threads, or add layers of transverse fibers of a suitable width, that is, not covering the entire width of the web.

[0027] Advantageously, the matrix material is a thermoplastic. Compared to thermosetting materials, this matrix offers several interesting characteristics. These include recyclability through remelting and granulation. Another advantage is the weldability of thermoplastic materials, which allows for welding profiles to intermediate components. In the case of reactive thermoplastic pultrusion, the precursors of the thermoplastic resin are also much more fluid before polymerization than in thermosetting chemistry, enabling very thorough impregnation of the textiles and resulting in a profile with a very high density of reinforcing material.

[0028] According to a specific design, the profile has at least one first flange extending from the tube, this first flange being formed by one of the overlapping zones. The first flange protrudes from the tube, and this protrusion is fully bonded to the profile. Since the two sheet edges are joined to form the flange, it is particularly strong.

[0029] According to a design feature, the tube has a substantially flat bearing surface, the first flange extending to the edge of said bearing surface in a direction substantially perpendicular to the bearing surface and including a return extending parallel and opposite to the bearing surface to define a groove. A groove suitable for receiving a flat element is thus obtained directly in the profile.

[0030] According to another complementary arrangement, the profile includes a second flange extending opposite the first flange relative to the tube, in the same direction as the return and parallel to the bearing face. This second flange can be used to secure the object made with this profile or to provide mechanical reinforcement to the profile.

[0031] According to a specific design, the tube has at least one internal shell underlying at least part of one of the outer shells and extending along an inner side of the tube. This shell, for example, has a C-shaped configuration when viewed in cross-section of the profile, resulting in a stronger tube. Multiple internal shells can be used to adjust the mechanical strength of the profile.

[0032] According to an improvement, the profile includes cross-sectional extensions in which the reinforcing material is formed by longitudinal fiber strands. These cross-sectional extensions allow for refining the profile's geometry, for example by creating reliefs, filling the junction zone between shells, or refining the extreme edge of the overlap zone.

[0033] According to an improvement, the reinforcing material is derived from the webs at a minimum of 80% by volume, preferably at least 90% by volume. The reinforcing material consists primarily of the webs. Fibers may be added longitudinally, for example, around the periphery of the profile to facilitate the introduction of the webs into the polymerization unit by a carrying effect, or to supplement the filling of the profile section in certain areas, but only marginally.

[0034] As an advantageous characteristic, the reinforcing material represents at least 50% of the profile's volume, and preferably at least 60%. A high reinforcement ratio ensures significant profile rigidity and strength. This high reinforcement ratio is made possible, in particular, by the use of a reactive thermoplastic resin.

[0035] As an example, the profile is used to make a frame for a photovoltaic or thermal solar panel, a thermal break strip, a battery support, or a window or door frame or threshold.

[0036] The invention also relates to a panel frame formed by assembling sections of pultruded profiles as defined above, with brackets inserted into the tubular parts of the profiles to connect the sections together. Such a frame can be used, in particular, in the manufacture of solar panels.

[0037] According to an improved method, each section is welded to the brackets inserted into it. The welding is performed, for example, using high-frequency currents or ultrasound. This assembly technique is particularly advantageous when the profile matrix is ​​made of thermoplastic material. Brief description of the figures

[0038] The invention will be better understood and other features and advantages will become apparent upon reading the following description, the description referring to the attached drawings, among which:

[0039] - la is a cross-sectional view of a profile according to a first embodiment of the invention; - la is a cross-sectional view of a profile according to a second embodiment of the invention; - la is a cross-sectional view of a profile according to a third embodiment of the invention; - la is a cross-sectional view of a profile according to a fourth embodiment of the invention; - la is a top view of a frame made with profiles; - la is a schematic view of a pultrusion installation for making a profile according to the invention; - la is a cross-sectional view of a profile according to a fifth embodiment of the invention. Detailed description

[0040] A profile 7 according to a first embodiment of the invention is shown in the figure. The profile 7 comprises a chamber 70 delimited by a tube 71 of substantially rectangular cross-section. A first wing 72 and a second wing 73 extend respectively from the tube 71, each of the wings 72, 73 being in the continuation of one of the walls 711, 712 of the tube 71.

[0041] The tube 71 has a substantially flat bearing face 715 supported by a short side 714, the first wing 72 extending to the limit of said bearing face 715 in a direction substantially perpendicular to the bearing face 715, that is to say in the extension of a long side 711. The first wing 72 further has a return 721 extending parallel and opposite the bearing face 715 to delimit a groove 74 between the first wing 72 and the bearing face 715.

[0042] The second wing 73 extends to the top of the tube 71 opposite the first wing 72 in the same direction as the return 721 and parallel to the support face 715.

[0043] The profile 7 is made of composite material, consisting of a reinforcing material encased in a synthetic matrix, preferably thermoplastic. The reinforcing material comprises two layers of textile, which, together with the thermoplastic matrix, form shells 75 and 76. One of the shells 75 forms part of the cross-section of the tube 71, including a short side 712 and a long side 711 of the rectangular section. The edges 751 of the first shell 75 are extensions of the long and short sides 711 and 712, respectively, forming part of the first wing 72 and the second wing 73, respectively. A second shell 76 forms the remaining part of the cross-section of the tube 71, including the other short side 714 and the other long side 713 of the rectangular section.The edges 761 of the second hull 76 extend substantially at right angles beyond the short and long sides 714, 713 to form part of the first wing 72 and the second wing 73, respectively. The reinforcing material of the first wing 72 is formed by the overlapping of an edge 751 of the first hull 75 and an edge 761 of the second hull 76. Similarly, the reinforcing material of the second wing 73 is formed by the overlapping of an edge 751 of the first hull 75 and an edge 761 of the second hull 76. In addition to the two outer layers 75, 76, the reinforcing material is supplemented by cross-sectional extensions 77 at the wingtips 72, 73, inside the tube 71 at the angles at the junction between the two outer layers 75, 76, on the inside of the long side 713 or in the form of bosses on the inside of the short sides 712, 714.Thus, the reinforcing material from the external layers 75, 76 represents more than 95% of the total volume of reinforcing material.

[0044] The textile of each layer is a non-interlaced, multi-axial reinforcing textile. The reinforcing material of each tube wall is made up almost entirely of a single layer of one of the layers 75, 76. Similarly, almost all of the reinforcing material of each wing 72, 73 is provided by the superposition of the two layers.

[0045] In a second embodiment of the profile, as shown in cross-section on the figure, the profile 7' differs from that of the first embodiment in that the tube 71' has a first internal shell 78 in a sheet of textile underlying the external sheets 75, 76 against an internal side of the tube 71', along the short sides 712, 714 and along the long side 711 in the extension of the first wing 72. This makes it possible to obtain a tube 71', and therefore a profile 7', of greater mechanical resistance.

[0046] In a third embodiment of the profile, as shown in cross-section on the figure, the 7'' profile differs from that of the second embodiment in that the 71'' tube has a second internal shell 79, but which extends along the long side 713 near the second wing 73.

[0047] In an unrepresented variant, the tube comprises both the first and second inner shells, one of the shells being superimposed on the other along the short sides 712, 714.

[0048] In a fourth embodiment, shown in the figure, the 7" profile differs from the first embodiment in that it receives an external layer 701 of a second thermoplastic material. The thickness of the layer 701 is, for example, between 0.5 and 1.5 mm.

[0049] A profile 7, according to any of the embodiments described above, is used, for example, to create a frame 9 for a photovoltaic or thermal solar panel as shown in the figure. Such a frame comprises four mitered sections 90 of the profile 7 joined together in the form of a rectangle. At each corner, a bracket 91 with two arms 910 is used to join two profile sections 90 together. For this purpose, one of the arms 910 of the bracket is inserted into the chamber 70 of the profile tube 71, preferably with a tight fit. Furthermore, each arm 910 is welded to the profile section 7 it receives, for example, by ultrasonic welding through the wall of the profile 7 in contact with the arm 910 of the bracket 91. In an alternative embodiment not shown, the bracket has straight stops against which the ends of the sections bear.The angle of the frame is then formed by the brackets, which are thus at least partially visible. The advantage is that the sections are cut straight and there is no waste as in the case of a miter cut.

[0050] In a fifth embodiment, the profile shown in the figure is intended for manufacturing thermal break strips used in aluminum window frame profiles. The 7" profile comprises a tube 71" with a substantially oblong cross-section, extended by first and second flanges 72" and 73". The 7" profile is formed by two shells originating from two layers 74" and 75", separated at the tube 71" and overlapped at the flanges 72" and 73". At the ends of the flanges 72" and 73", additional sections 77" are inserted between the layers 74" and 75", so that the flanges 72" and 73" terminate in a dovetail shape. This shape is intended to be gripped and crimped into a groove of an aluminum profile, not shown, for assembly.

[0051] A pultrusion profile manufacturing installation will now be described in relation to [the relevant section]. The pultrusion installation comprises, successively:

[0052] - a reeling unit 1 for reeling rovings M of fibers forming a reinforcing material, also called "rovings" in English, - an assembly unit 2 which receives the rovings M and produces the webs 75, 76 of reinforcing material; - a preheating unit 3 for the webs 75, 76 which brings the fibers from the assembly unit 2 to a temperature close to the melting temperature of a resin; - a polymerization unit 4 straight, composed of an impregnation unit 41 for impregnating the webs 75, 76 with a reactive mixture and a polymerization unit 42; - a mixing unit 5 for the reactive mixture to mix precursors and supply the reactive mixture in liquid form to the impregnation unit; - a coextrusion unit 6 which deposits an outer layer on the profile 7 and forms the profile 7''';- and a pulling unit 8 to pull the profile 7''' out of the co-extrusion unit, drawing the sheets 75, 76 through the installation from their assembly.;

[0053] In mixing unit 5, precursors are stored in liquid form in tanks A, B, and C. The precursors are conveyed to mixing unit 5 at a controlled flow rate and mixed to form the liquid reactive mixture. The reactive mixture is injected into impregnation unit 41 to wet the sheets 75 and 76 throughout their cross-section and form an intermediate composite material 7a.

[0054] In the polymerization unit 42, the intermediate composite material 7a is mounted and maintained at temperature. The reactive mixture reacts under the influence of temperature and polymerizes at least partially to form a thermoplastic resin.

[0055] Profile 7 exits the polymerization unit 42 and, sufficiently hardened, enters a co-extrusion die 60, which is part of the co-extrusion unit 6. The co-extrusion unit 6 includes an extruder 61 that supplies the second molten thermoplastic material under pressure to the co-extrusion die 60. The co-extrusion die 60 then deposits the outer layer 701 around profile 7 to produce profile 7'''. The co-extrusion unit 6 is optional, and profile 7 could be extracted directly by the drawing unit 8, without depositing an outer layer.

[0056] A cutting unit, not shown, cuts profile 7 to length. After the profiles are cut, they are stored in a temperature-controlled chamber so that polymerization can continue.

[0057] The pulling unit 8 includes, for example, a pair of tracks which grip the profile 7 during pulling.

[0058] The assembly unit 2 allows for the production of non-intertwined multi-axial reinforcement sheets 75, 76 directly and continuously upstream of the polymerization unit 4. The sheets 75, 76 are shaped before or after their introduction into the polymerization unit.

[0059] Optionally, a second unwinding unit 1' provides additional strands M' which form the additional reinforcements 77 or a mat on the surface of the sheets 75, 76 to facilitate the introduction of the sheets 75, 76 into the polymerization unit.

[0060] The process is a thermoplastic reactive pultrusion process. When using polyamide, the precursors are, for example, caprolactam, an activator, and a catalyst, which are maintained at a temperature above 80°C in the reservoirs. The layers 75 and 76 are heated in the preheating unit 3 to above 80°C as well. In the impregnation unit 41, the reactive mixture is injected at a flow rate sufficient to completely impregnate the fibers, but without reflux. The polymerization unit 42 is heated according to a controlled gradient to the outlet at a temperature chosen within a range of approximately 140 to 250°C, depending on the geometries. The reactive mixture polymerizes throughout the polymerization unit 42 and takes the shape of the profile.

[0061] Alternatively, the reactive mixture produces polymethyl methacrylate with suitable precursors and temperatures.

[0062] The invention is not limited to the embodiments described by way of example. A profile could be formed with a single sheet whose two edges are superimposed either by forming a loop or by forming a wing.

Claims

A method for manufacturing a continuous composite profile, the profile (7) comprising at least one chamber (70) and consisting of a reinforcing material embedded in a synthetic matrix, wherein at least one layer of textile forming the reinforcing material of a shell (75, 76, 78, 79) is supplied to a tool (4) in which the layers (75, 76, 78, 79) are formed and introduced, and wherein the synthetic material is intimately bonded to the layer(s), the chamber (70) is delimited by at least one layer, each layer comprising two edges (751, 761), each edge (751, 761) being superimposed on another edge (751, 761) in an overlap zone, and the synthetic material is hardened in the tool so that the layers form the shells (75, 76), the shell(s) (75, 76) around the chamber (70) forming a tube (71),characterized in that the reinforcing material in the profile is derived from the layers at a rate of at least 50% by volume and represents at least 50% of the volume of the profile. Method according to claim 1, wherein the textile sheet(s) are manufactured by an assembly unit (2) directly in continuous operation upstream of the tooling (4). A process according to claim 1 or 2, wherein the synthetic material is supplied to the tooling in a fluid state in the form of a reactive mixture, the process being a pultrusion process, the tooling being a polymerization unit (4) for obtaining hardening by polymerization of the reactive mixture into a composite material matrix. A process according to claim 3, wherein the synthetic material after polymerization is a thermoplastic material. A process according to claim 4, wherein the reactive mixture produces a synthetic material selected from a group comprising polyamides and polymethyl methacrylate. A process according to any one of claims 1 or 2, wherein the synthetic material is thermoplastic material previously incorporated in the form of yarns or powder during the manufacture of the textile before the shaping of the sheet(s). A method according to any one of claims 1 to 6, wherein the assembly unit (2) forms non-interlaced multi-axial reinforcement textiles. A method according to any one of claims 1 to 6, wherein the assembly unit is a weaving unit (2) which forms fabrics. A method according to any one of the preceding claims, wherein the assembly unit (2) forms the textile with variations in thickness depending on the position in the width. A method according to any one of the preceding claims, wherein at least one drive layer formed by longitudinal fibers is provided at the periphery of the webs to facilitate the insertion of the webs and their drive into the tooling (4). A method according to any one of the preceding claims, in which a co-extrusion is carried out at the exit of the tooling (4) to coat the profile (7) with a layer (701) of a second thermoplastic material. Composite profile comprising at least one chamber (70), characterized in that the chamber (70) is delimited by at least one shell, each shell (75, 76) comprising two edges (751, 761) and being formed by a reinforcing material in the form of at least one sheet of textile impregnated with a synthetic matrix, each edge (751, 761) being superimposed on another of the edges (751, 761) in an overlap zone, the shell(s) (75, 76) around the chamber (70) forming a tube (71), the reinforcing material being derived from the sheets at least 50% by volume and representing at least 50% of the volume of the profile. Profile according to claim 12, in which the chamber is delimited by internal faces of two shells, each edge of each of the shells being connected to one of the edges of the other shell by direct contact on an extension of the internal faces. Profile according to claim 12 or 13, wherein the textile of the layers is a non-interlaced multi-axial reinforcement textile. Profiled according to claim 12 or 13, wherein the textile of the tablecloths is a fabric. Profiled according to any one of the preceding claims 12 to 15, wherein the textile has variations in thickness depending on the position in the width. Profile according to any one of claims 12 to 16, wherein the matrix material is a thermoplastic material. Profile according to any one of claims 12 to 17, characterized in that it comprises at least one first wing (72, 73) extending from the tube (71), the first wing (72, 73) being formed by one of the overlap zones. Profile according to claim 18, in which the tube (71) has a substantially flat bearing face (715), the first wing (72) extending to the limit of said bearing face (715) in a direction substantially perpendicular to the bearing face (715) and having a return (721) extending parallel and opposite the bearing face (715) to delimit a groove (74). Profile according to claim 18 to 19, characterized in that it comprises a second wing (73) which extends opposite the first wing (72) with respect to the tube (71) in the same direction as the return (721) and parallel to the bearing face (715). Profile according to any one of claims 12 to 20, characterized in that it comprises section complements (77, 77") in which the reinforcing material is formed by strands of longitudinal fibers. Profile according to any one of claims 12 to 21, wherein the reinforcing material is derived from the plies at least 80% by volume, preferably at least 90% by volume. Profile according to any one of claims 12 to 22, wherein the reinforcing material represents at least 50% by volume of the profile (7), preferably at least 60% by volume of the profile (7). Profile according to any one of claims 12 to 23, characterized in that it is used to make a frame (9) for a photovoltaic or thermal solar panel, a thermal break strip, a battery support, or a window or door frame or threshold. Panel frame, characterized in that it is formed by the assembly of sections (90) of profiles according to any one of claims 12 to 24, with brackets (91) inserted in the tubular parts of the profiles to connect the sections (90) together.

Images