CN101044017B - 用于模塑大型复合结构的浸渍织物 - Google Patents

用于模塑大型复合结构的浸渍织物 Download PDF

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CN101044017B
CN101044017B CN2005800361066A CN200580036106A CN101044017B CN 101044017 B CN101044017 B CN 101044017B CN 2005800361066 A CN2005800361066 A CN 2005800361066A CN 200580036106 A CN200580036106 A CN 200580036106A CN 101044017 B CN101044017 B CN 101044017B
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impregnate fabric
fabric
impregnate
enhancement layer
tow
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CN101044017A (zh
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D·R·哈特曼
M·W·邓恩
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Owens Corning Fiberglas Technology Inc
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Owens Corning Fiberglas Technology Inc
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Abstract

一种浸渍织物(10)，包括：从由连续长丝垫席、直接短切垫席、直接连续垫席和这些垫席的结合物构成的组中选择的垫席(12)，以及机织粗纱或粘合增强层(14)。所述垫席和所述机织粗纱增强层被缝合在一起。所述连续长纤维垫席包括：E-玻璃纤维和/或ECR-玻璃纤维、粘合剂和浆料。

Description

用于模塑大型复合结构的浸渍织物
技术领域
本发明总体上涉及一种浸渍织物以及一种新颖的连续长丝垫席和一种新颖的粘合剂，所述织物能够被模塑为大型复合结构。
背景技术
在本领域公知的加强织物由形成机织材料、针织材料和无纺材料的纤维材料制成。典型地通过玻璃纱线、碳纱线和芳族聚酰胺纱线形成织物，且多个织物层被堆叠并被切成干织物套件或预制坯。所述预制坯随后被浸渍或浸入树脂粘合剂并被固化以形成刚性复合物。
典型地，玻璃加强纤维垫席经预成型，随后被置于模具中以模塑为纤维加强制品。玻璃纤维加强垫席用于需要必要强度的情形，如用于卡车的防护板、汽车底盘或客车的构件等。例如，连续生丝(strand)垫席的层和单向或多向加强材料的层分别地进行制造。这些层被单独地置于一套预成型筛网中，所述预成型筛网一般包括上部筛网和下部筛网。所述上部筛网和下部筛网一起移动以使多层结构符合预成型筛网的形状。因此所述多层结构成形为所称为的预制坯。所述预制坯随后被置于模具中，并以合适的树脂类材料注入以制成纤维加强制品。
本发明的受让人所有的于2005年3月31日公开的美国专利公开No.2005-0070182公开了一种无卷曲浸渍加强织物。这种单向织物在较大尺寸的丝束之间具有间隔开的较小尺寸的丝束。由较大丝束之间的较小丝束形成的“通道”使树脂更快速地浸渍并提高了生产率。
本发明涉及一种改进的浸渍织物，所述浸渍织物在包括VIP、RTM和RTM Lite或VARTM处理的封闭模塑处理的范围内更好地优化了配套(kitting)、预成型、加工的一致性、树脂浸渍速率、凝固厚度、表面美观性、以及复合物的结构性能。这代表由船舶(marine)、航空(wind)、建造、运输和工业用户使用的复合物封闭模塑过程的全部范围。另外，本发明还涉及一种新颖的连续长丝垫席和用于制造这种改进的浸渍织物垫席的粘合剂。
发明内容
所述浸渍织物包括：从由连续长丝垫席、直接短切垫席、直接连续垫席和这些垫席的结合物构成的组中选择的垫席，以及机织粗纱或粘合增强层。在一种可行的实施例中所述垫席和所述机织粗纱增强层被缝合在一起。
更具体而言，所述垫席通过从由玻璃纤维、碳纤维、石墨纤维、玻璃碳纤维、非石墨碳纤维、硼单块石墨纤维、硼单块非石墨碳纤维、硅树脂、芳族聚酰胺、陶瓷纤维、热塑性聚合物纤维、天然纤维和其混合物构成的组中选择的材料构成。诸如棉花、洋麻、剑麻、黄麻之类的天然纤维可以单独使用或与任意的以上所述的材料结合使用。所述机织粗纱或粘合加强层也可以由同以上所列材料相同的材料构造成。
典型地，机织粗纱加强层14的单位面积重量介于约8至约60oz/sq.yd(约0.27至约2.03kg/sq.m)之间。进一步，机织粗纱加强层从平纹式样、斜纹式样和缎纹式样的组中进行选择。所述机织粗纱加强层包括多个平行的丝束，其中至少两个丝束具有不同的每磅的码数，以形成间隔开的通道。典型地，两个丝束中的第一丝束的每磅的码数A介于约750至约2500yds/lb(约1511.9至约5039.7m/kg)之间，且所述两个丝束中的第二丝束的每磅的码数B介于约52至约450yds/lb(约104.8至约907.2m/kg)之间。
根据本发明另一种可行的实施例，所述浸渍织物还包括铺面垫席。所述垫席夹在所述铺面垫席和所述机织粗纱加强层之间。
根据本发明一种特别的实施例，所述浸渍织物的垫席是包括从E-玻璃纤维和/或ECR-玻璃纤维、粘合剂和浆料的连续长丝垫席。更具体而言，所述连续长丝垫席在所述纤维上包括：重量百分比介于约80至约99之间的玻璃纤维；重量百分比介于约1至约20之间的粘合剂；以及重量百分比介于约0.01至约1之间的浆料。所述玻璃纤维被设置为玻璃长丝束。所述玻璃长丝束的每束包括约20至约140个玻璃长丝。各所述玻璃长丝的平均直径介于约11微米至约26微米之间。所述玻璃长丝束的直径介于约0.127mm至约3.175mm之间。成圈率在约2.0至约8.0之间的范围内。
所述粘合剂是聚酯或诸如环氧树脂和环氧酚醛的环氧相容性粘合剂环氧亲和性粘合剂。所述聚酯粘合剂被研磨成粒度介于约25mm至约200mm之间。所述粘合剂还包括滑石和过氧化苯甲酰。更具体而言，所述粘合剂包括：重量百分比介于约92.5至约99.8之间的聚酯；重量百分比介于约0.01至约5之间的滑石；以及重量百分比介于约0.1至约2.5之间的过氧化苯甲酰。
更进一步，所述连续长丝垫席具有以丙酮可萃取物表示的固化度介于约50％至约100％之间。更典型地，所述连续长丝垫席具有以丙酮可萃取物表示的固化度介于约60％至约90％之间。
根据本发明的另一方面，提供了一种连续长丝垫席。所述连续长丝垫席包括E-玻璃纤维和/或ECR-玻璃纤维、粘合剂和浆料。所述连续长丝垫席包括重量百分比介于约90至约98之间的E-玻璃或ECR-玻璃纤维；重量百分比介于约2至约10之间的粘合剂；以及重量百分比介于约0.1至约1之间的浆料。所述玻璃纤维被设置为玻璃长丝束。所述玻璃长丝束的每束包括约20至约140个玻璃长丝。各所述玻璃长丝的平均直径介于约11微米至约26微米之间。所述玻璃长丝束的直径介于约0.127mm至约3.175mm之间。成圈率在约2.0至约8.0之间的范围内。以丙酮可萃取物测量的固化度介于约50％至约100％之间并且更典型地介于60％至90％之间。
在一种特别有利的实施例中，所述连续长丝垫席包括每束或每圈生丝具有介于约44至约50长丝的E-玻璃纤维或ECR-玻璃纤维。所述束的平均直径为约0.3048mm，并且其范围介于约0.127至约1.27之间。所述生丝对于垫席结构或优选的成圈率介于大约6.0至大约6.6之间。
根据本发明的另一方面，提供一种粘合剂用于制备玻璃纤维垫席。所述粘合剂包括：重量百分比介于约95至约99.8之间的聚酯；重量百分比介于约0。05至约3之间的滑石；以及重量百分比介于约0.2至约2之间的过氧化苯甲酰。所述聚酯粘合剂被研磨成粒度介于约25mm至约200mm之间。所述聚酯以乙二醇和富马酸为基础。
在以下的说明中通过对最适合实施本发明的一些方式进行说明而简单地示出并描述了本发明的几个不同的实施例。应当理解的是，本发明能够以其它不同的实施例进行实施，并且其细节能够在多个显而易见的不脱离本发明范围的方面进行改型。因此，附图和文字说明本质上是说明性的而非限制性的。
附图说明
并入说明书并组成说明书一部分的附图示出了本发明的几个方面，并与说明书一起解释本发明的特定原理。在附图中：
图1是本发明的浸渍织物的一个可行实施例的局部截面立体图；
图1a是如图1所示的浸渍织物的完整横截面图；
图2是本发明的浸渍织物的另一个可行实施例的局部截面立体图；以及
图2a是如图2所示的浸渍织物的完整横截面图。
现将详细参考本发明的优选实施例，其实例在附图中示出。
具体实施方式
本发明的浸渍织物10的第一实施例在图1和图1a中示出。如图所示，浸渍织物10包括垫席12和机织粗纱或粘合加强层14。垫席12和机织粗纱加强层14都可以从玻璃纤维、碳纤维、石墨纤维、玻璃碳纤维、非石墨碳纤维、硼单块石墨纤维、硼单块非石墨碳纤维、硅树脂、芳族聚酰胺、陶瓷纤维、热塑性聚合物纤维、天然纤维(例如，棉花、洋麻、剑麻、黄麻)以及它们的混合物的构成的组中选择的材料构成。垫席12和机织粗纱加强层14当然可以根据需要由同以上所列材料相同或不同的材料构成。
机织粗纱加强层14的单位面积重量介于大约8至大约60oz/sq.yd(大约0.27至大约2.03kg/sq.m)之间。机织粗纱加强层14从平纹式样、斜纹式样和缎纹式样的构成的组中进行选择。机织粗纱或粘合加强层14还包括多个平行的丝束18、20，其中至少两个丝束具有不同的每磅的码数，以形成间隔开的通道21。两个丝束中的第一丝束18的每磅的码数A介于大约750至2500yds/lb之间(大约1511.9至大约5039.7m/Kg)。两个丝束中的第二丝束20的每磅的码数B介于大约52至大约450yds/lb之间(大约104.8至大约907.2m/Kg)。通过将一个或多个较小的第一丝束18置于两个或多个较大的第二丝束20之间，设置通道21。典型的机织粗纱加强层14包括一组这些通道21，所述通道21的组在模塑处理中使树脂迅速地浸渍通过浸渍织物10。
所述丝束18、20的间距典型地由在模塑处理中使用的树脂确定。更具体而言，粘性较大的树脂在单位表面积上需要更多的通道，以在模塑处理中更好地促进树脂的流动。可选择地，粘性较小的树脂更易于流动，单位表面积上需要较少的通道。在这种情形时在大量的较大丝束20之间需要少量的较小丝束18。
机织粗纱或粘合加强层14典型地包括单向纤维取向.可以使用多种方法将初级纤维维持在单向层的适当的位置中.这些方法包括现有技术中已知的机织、缝合和粘合.在一个特别有利的实施例中，所述层14由无卷曲的经编针织物(另外还称为缝编织物)构成.在示例性实施例中，机织粗纱或粘合加强层14的丝束18、20通过次级非结构性的缝合线22保持在适当的位置.典型地所述缝合线22可是聚酯线或任何其它在本领域中常规使用的线.
垫席12和机织粗纱或粘合加强层14通过适合的方法连接在一起。在示例性实施例中，所述连接通过使用常规的缝编技术和类型来缝编诸如经纱、特里科经编针织物、改进的特里科经编针织物或promat织物而完成。为此，可以使用本领域中已知的常规机器(如Liba缝编机)。
如图1和图1a所示，浸渍织物10还可以包括第二机织粗纱或粘合加强层24。所述第二机织粗纱加强层24具有与第一机织粗纱加强层14类似的结构，即：第二机织粗纱或粘合加强层包括多个平行的丝束26、28，其中至少两个丝束具有不同的每磅的码数，以形成间隔开的通道用于注入树脂。所述丝束26、28不必具有和第一机织粗纱加强层14中丝束18、20相同的每磅的码数。但是应当理解的是，第一机织粗纱加强层14的丝束18、20沿第一方向延伸，而第二机织粗纱加强层24的丝束26、28沿与第一方向偏置的第二方向延伸。典型地，所述偏置大致为90度。这种结构性设置使浸渍织物10增加了额外的强度。
浸渍织物10的可选实施例如图2和2a所示。所述实施例包括与如上所述的相对于图1示出的实施例基本相同的垫席12和机织粗纱或粘合加强层14。另外，所述浸渍织物10包括铺面垫席30。所述铺面垫席30连接至垫席12与机织粗纱加强层14相对的面，从而垫席12被夹在铺面垫席30和机织粗纱加强层14之间。铺面垫席30由诸如另一种连续纤维垫席的印浆布层粘连介质(print blocking media)或组合有玻璃纤维、聚酯纤维、天然纤维(例如，棉花、洋麻、剑麻、黄麻)、聚合物颗粒和粘合剂的面纱料形成。铺面垫席30可以通过纺丝粘合、湿法粘合、干法粘合和针刺连接至垫席12。
如上所述，垫席12可以是连续长丝垫席。为了实现本申请文件的目的，“连续长丝”解释为在复合物凝固时适当地用于湿润或粘着树脂或聚合物的单个经处理的、确定尺寸或完成的纤维准直组件。
还是为了实现本申请文件的目的，“连续长丝垫席”解释为连续成束纤维的随意卷绕设置，所述连续成束纤维在形成平面各向同性的垫席的过程中具有由成圈率限定的方向。使可用的连续长丝垫席12采用大约2.0至大约8.0之间，并且典型地介于大约6.0至大约6.6之间的成圈率(成圈率是生丝或丝束速度/振动速率)制成。
特别用于本发明的连续长丝垫席12还包括E-玻璃和/或ECR-玻璃纤维、粘合剂和浆料。这种玻璃纤维设置为玻璃长丝束。所述玻璃长丝束的每单位丝束包括大约20至大约140根长丝。各长丝的平均直径介于大约11至大约26微米之间。所述丝束的直径介于大约0.127至大约3.175mm之间。
在一个特别有用的实施例中，长丝的平均直径介于大约17.0和大约20.0微米之间。进一步讲，每束或每圈生丝有大约44至大约55根长丝。所述生丝或丝束的平均直径为大约0.3048mm，并且所述丝束的直径介于大约0.127至大约1.27mm的范围内。所述生丝对于垫席结构或优选的成圈率介于大约6.0至大约6.6之间。
所述粘合剂是聚酯或如粉末状的环氧树脂或酚醛环氧树脂的环氧相容性粘合剂。环氧树脂包括由表氯醇和双酚A制成的粘合剂。酚醛环氧树脂由表氯醇和酚醛树脂(苯酚-甲醛)反应制成的树脂。
在一个可行的实施例中，聚酯粘合剂以乙二醇和富马酸为基础.所述粘合剂还包括滑石和过氧化苯甲酰.所述粘合剂的典型的应用是研磨成粒度介于大约25至200mm之间.滑石作为结晶促进剂加入.所述粘合剂通过低温下将结晶的聚合物和少量的硬脂酸锌研磨成需要的粒度而制备.这种粉末随后与过氧化苯甲酰进行干混合.更具体而言，所述粘合剂包括大约95至大约99.8重量百分比的聚酯，大约0.05至大约3重量百分比的滑石以及大约0.2至大约2重量百分比的过氧化苯甲酰.
在连续长丝垫席12中使用的浆料包括一种或多种组合有水、乙酸、硅烷和一种杀虫剂的配方。用于本发明的硅烷偶联剂包括但不限于从General Electric Silanes中可获得A-187、A-171、A-174和A-1100硅烷。用于本发明的润滑剂包括但不限于由ICI America and Omega16407制造及出售的Cirrosol 185AE和185AN。用于本发明的杀虫剂包括但不限于含有二/三丁基氧化锡的季铵化合物。一个这种杀虫剂以Biomet 66为商标出售并从Atochem可获得。
连续长丝垫席12在输送链上通过传送玻璃长丝束经过粘合剂施加过程而制造。所述输送链的一部分被支撑在称为色浆盘的端部开口槽中。所述色浆液盘的目的是积聚足够的淤浆并完全没过非织造网一段时间。淤浆从位于色浆盘入口端上方的储器并朝向色浆盘(即，帘幕编码器(curtain coder))入口端供给。所述储器通过在储器最低端部分上的狭槽排出淤浆。所述储器和狭槽延伸过色浆盘的宽度。储器和狭槽的主轴线定向为垂直于处理的输送链上的机器方向(主轴线)。
淤浆从储器狭槽竖直向下地以连续的帘幕形式向玻璃生丝的非织造网的上表面排出。淤浆帘幕的速度随着淤浆从储器狭槽的排出速度、狭槽和网表面之间的竖直距离以及淤浆粘度变化而变化。
玻璃生丝的非织造网和输送链对淤浆流基本是可渗透的，从而使淤浆容易在玻璃生丝和输送链金属丝的周围流动，并向下流动至不可渗透的色浆盘。当来自储器的竖直淤浆流撞击色浆盘的平表面上(与色浆盘的表面垂直)时，所述竖直淤浆流再取向为水平流。当所述淤浆流与非织造网、输送链和色浆盘相互作用时，所述淤浆流通常再取向以沿与传送器和网相同的方向流动。来自色浆盘的淤浆的去除率随着淤浆向色浆盘的供应速率、输送链的厚度、输送链和淤浆的阻力、淤浆的粘度、色浆盘中淤浆的深度及其它因素变化而变化。由储器供给的淤浆的体积流量被设计为足以确保所述网当被承载通过色浆盘的大部分长度时被完全地浸没。所述淤浆流动通过玻璃生丝并且留下粘合剂沉积物，所述粘合剂沉积物在烤箱中随后被固化为粘合垫席结构。
为了使连续长丝垫席12允许得到所需的树脂浸渍，玻璃纤维束不能太大或靠得太近。这些方面均会影响垫席构造在树脂浸渍上的开放性和渗透性。用于本发明的连续长丝垫席12包括但不限于从本发明的受让人处可商业上获得的CFM8610、CFM8620、CFM8630、CFM8635、CFM8636、CFM8643。
影响RTM、RTM lite或VIP处理的树脂浸渍的因素在减小树脂粘度和增大垫席/纤维的平面渗透性的需求上遵循Darcy法则。平衡树脂浸渍和模塑一致性(mold conformability)的连续长丝垫席的渗透性已显示出通过成丝作用的减小、恰当的致密和粘合剂的固化而得以改善。垫席的随意卷绕、连续纤维和恰当浆料/粘合剂的的化学性质获得优良的复合物的机械的和结构的性能。为了实现所述申请文件的目的以丙酮的可萃取物检测固化度。通过丙酮的可萃取物检测的连续长丝垫席的固化度介于大约50％至大约100％之间，并且更典型地介于大约60％至90％之间。
包括在图1和图2中示出的本发明的浸渍织物10的多种实施例特别适用于模塑处理，在这种模塑处理中树脂必须移动通过织物以产生凝固的复合物。一种特殊的处理过程为树脂传递模塑(RTM)。树脂传递模塑(RTM)是这样一种处理，即通过该处理树脂在低粘度和低压下被泵入封闭的、包括干织物(即，织物10)的预制坯的模塑模具组中，以使树脂浸入所述预制坯且制成纤维加强复合物部分。所述RTM处理能够被用于生产形状复杂的低成本复合物部分。这些部分连同内模线(mold line)和外模线控制表面一起典型地需要连续纤维的加强。在大型结构和小型结构中包括并且置放连续纤维加强的能力设定了除其它液体模塑处理的之外的RTM。
所述织物10还用于真空辅助树脂传递模塑(VARTM)系统。在VARTM中，预制坯被诸如织物10之类的柔性片材或衬垫覆盖。所述柔性片材或衬垫夹在模具上以在包封件中密封预制坯。随后将催化基质树脂引入所述包封件以使所述预制坯润湿。通过真空管将包封件的内部抽真空以使柔性片材向预制坯陷缩。真空抽吸树脂通过预制坯并帮助避免在成品中形成气泡或空隙。当受到真空时，基质树脂固化。通过应用真空能够将在固化处理中产生的任何气雾抽走。本发明的织物10适用于标准的真空浸渍模塑处理以及加强织物在真空下的处理。
总之，本发明的织物10能够提供诸多优点。所述织物10的特征在于优秀的操作性能，易于使用以及无法超越的树脂渗透性。更快的流速会产生更高的产量和更高的模具周转率，同时通过消除局部树脂分布介质而潜在地降低了成本。进一步，对环境的VOC损耗降低。而且，能够以最少的劳动力和成本实现层压主体。
为了图示和说明的目的提出了对本发明优选实施例的上述说明。所述说明并非穷举或将本发明限制于公开的具体形式。根据上述指导可以进行明显的改型或变化。
所选择并描述的实施例对本发明的原理提供了最好的解释，由此本发明的实际应用能够使本领域的普通技术人员以多种实施例并且通过适于具体的预期用途的多种改型利用本发明。当根据对权利要求赋予合理、合法及等价的权利所限定的范围进行解释时，所有的这些改型和变化均落入由附属权利要求限定的本发明的范围内。附图和优选实施例并非并且不是为了以任何方式限定权利要求的通常意义以及合理及宽泛的解释。

Claims (46)

1.一种浸渍织物(10)，所述浸渍织物包括：
垫席(12)，其从由连续长丝垫席、直接短切垫席、直接连续垫席和这些垫席的结合物构成的组中进行选择；以及
机织粗纱或粘合加强层(14)，所述机织粗纱或粘合加强层包括多个平行的丝束(18，20)，其中至少两个丝束具有不同的每磅的码数，以形成间隔开的通道(21)。
2.如权利要求1所述的浸渍织物，其中所述垫席和所述机织粗纱或粘合加强层被缝合在一起。
3.如权利要求1所述的浸渍织物，其中所述垫席通过从由玻璃纤维、碳纤维、玻璃碳纤维、硅树脂、陶瓷纤维、热塑性聚合物纤维、天然纤维和其混合物构成的组中选择的材料构造成。
4.如权利要求1所述的浸渍织物，其中所述机织粗纱或粘合加强层通过从由玻璃纤维、碳纤维、玻璃碳纤维、硅树脂、陶瓷纤维、热塑性聚合物纤维、天然纤维和其混合物构成的组中选择的材料构造成。
5.如权利要求4所述的浸渍织物，其中所述机织粗纱或粘合加强层的单位面积重量介于每平方米0.27千克至2.03千克之间。
6.如权利要求5所述的浸渍织物，其中所述机织粗纱或粘合加强层从由平纹式样、斜纹式样和缎纹式样构成的组中选择。
7.如权利要求1所述的浸渍织物，其中所述两个丝束中的第一丝束的每磅的码数A介于750至2500码/磅之间，且所述两个丝束中的第二丝束的每磅的码数B介于52至450码/磅之间。
8.如权利要求1所述的浸渍织物，进一步包括铺面垫席(30)。
9.如权利要求8所述的浸渍织物，其中所述垫席夹在所述铺面垫席和所述机织粗纱或粘合加强层之间。
10.如权利要求1所述的浸渍织物，其中所述连续长丝垫席包括：从由E-玻璃纤维、ECR-玻璃纤维和这些纤维的混合物构成的组中选择的玻璃纤维、粘合剂和浆料。
11.如权利要求10所述的浸渍织物，包括：重量百分比介于80至99之间的玻璃纤维；重量百分比介于1至20之间的粘合剂；以及重量百分比介于0.01至2之间的浆料。
12.如权利要求11所述的浸渍织物，其中所述玻璃纤维被设置为玻璃长丝束。
13.如权利要求12所述的浸渍织物，其中所述玻璃长丝束中的每束包括20至140个玻璃长丝。
14.如权利要求13所述的浸渍织物，其中所述玻璃长丝束的所述玻璃长丝的平均直径介于11微米至20微米之间。
15.如权利要求14所述的浸渍织物，其中所述玻璃长丝束的平均直径为0.3048mm，且直径范围介于0.127mm至1.27mm之间。
16.如权利要求11所述的浸渍织物，其中所述粘合剂从由聚酯和环氧相容性粘合剂构成的材料组中选择。
17.如权利要求16所述的浸渍织物，其中所述聚酯粘合剂被研磨成粒度介于25mm至200mm之间。
18.如权利要求17所述的浸渍织物，其中所述粘合剂还包括滑石。
19.如权利要求17所述的浸渍织物，其中所述粘合剂还包括过氧化苯甲酰。
20.如权利要求17所述的浸渍织物，其中所述粘合剂包括：
重量百分比介于95至99.8之间的聚酯；
重量百分比介于0.05至3之间的滑石；以及
重量百分比介于0.2至2之间的过氧化苯甲酰。
21.如权利要求10所述的浸渍织物，其中所述连续长丝垫席的成圈率介于2.0至8.0之间，且当以丙酮可萃取物进行测量时，固化度介于50％至100％之间。
22.如权利要求3或4所述的浸渍织物，其中所述碳纤维包括石墨纤维、非石墨碳纤维、硼单块石墨纤维、硼单块非石墨碳纤维。
23.如权利要求3或4所述的浸渍织物，其中所述热塑性聚合物纤维包括芳族聚酰胺纤维。
24.一种浸渍织物(10)，所述浸渍织物包括：
连续长丝垫席(12)；以及
机织粗纱或粘合加强层(14)，所述机织粗纱或粘合加强层包括多个平行的丝束(18，20)，其中至少两个丝束具有不同的每磅的码数，以形成间隔开的通道(21)。
25.如权利要求24的浸渍织物，其中所述垫席和所述机织粗纱或粘合加强层被缝合在一起。
26.如权利要求24所述的浸渍织物，其中所述垫席通过从由玻璃纤维、碳纤维、玻璃碳纤维、硅树脂、陶瓷纤维、热塑性聚合物纤维、天然纤维和其混合物构成的组中选择的材料构造成。
27.如权利要求24所述的浸渍织物，其中所述机织粗纱加强层通过从由玻璃纤维、碳纤维、玻璃碳纤维、硅树脂、陶瓷纤维、热塑性聚合物纤维、天然纤维和其混合物构成的组中选择的材料构造成。
28.如权利要求27所述的浸渍织物，其中所述机织粗纱加强层的单位面积重量为每平方米介于0.27千克至2.03千克之间。
29.如权利要求28所述的浸渍织物，其中所述机织粗纱加强层从由平纹式样、斜纹式样和缎纹式样构成的组中选择。
30.如权利要求24所述的浸渍织物，其中所述两个丝束中的第一丝束的每磅的码数A介于750至2500码/磅之间，且所述两个丝束中的第二丝束的每磅的码数B介于52至450码/磅之间。
31.如权利要求24所述的浸渍织物，其中进一步包括铺面垫席(30)。
32.如权利要求31所述的浸渍织物，其中所述垫席夹在所述铺面垫席和所述机织粗纱或粘合加强层之间。
33.如权利要求24所述的浸渍织物，其中所述连续长丝垫席包括：从由E-玻璃纤维、ECR-玻璃纤维和这些纤维的混合物构成的组中选择的玻璃纤维、粘合剂和浆料。
34.如权利要求33所述的浸渍织物，其中包括重量百分比介于90至98之间的玻璃纤维；重量百分比介于2至10之间的粘合剂；以及重量百分比介于0.1至1之间的浆料。
35.如权利要求34所述的浸渍织物，其中所述玻璃纤维被设置为玻璃长丝束。
36.如权利要求35所述的浸渍织物，其中所述玻璃长丝束中的每束包括20至140个玻璃长丝.
37.如权利要求36所述的浸渍织物，其中所述玻璃长丝束的所述玻璃长丝的平均直径介于11微米至20微米之间。
38.如权利要求37所述的浸渍织物，其中所述玻璃长丝束的平均直径为0.3048mm，且直径范围介于0.127mm至1.27mm之间。
39.如权利要求34所述的浸渍织物，其中所述粘合剂为聚酯。
40.如权利要求39所述的浸渍织物，其中所述聚酯粘合剂被研磨成粒度介于25mm至200mm之间。
41.如权利要求40所述的浸渍织物，其中所述粘合剂还包括滑石。
42.如权利要求40所述的浸渍织物，其中所述粘合剂还包括过氧化苯甲酰。
43.如权利要求40所述的浸渍织物，其中所述粘合剂包括：
重量百分比介于95至99.8之间的聚酯；
重量百分比介于0.05至3之间的滑石；以及
重量百分比介于0.2至2之间的过氧化苯甲酰。
44.如权利要求33所述的浸渍织物，其中所述连续长丝垫席的成圈率介于2.0至8.0之间，且当以丙酮可萃取物进行测量时，固化度介于50％至100％之间。
45.如权利要求26或27所述的浸渍织物，其中所述碳纤维包括石墨纤维、非石墨碳纤维、硼单块石墨纤维、硼单块非石墨碳纤维。
46.如权利要求26或27所述的浸渍织物，其中所述热塑性聚合物纤维包括芳族聚酰胺纤维。
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US20080206551A1 (en) 2008-08-28
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WO2006098773A1 (en) 2006-09-21
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ES2531736T3 (es) 2015-03-18
CA2582183C (en) 2014-03-25
EP1802453A1 (en) 2007-07-04
CN101575490A (zh) 2009-11-11
BRPI0516993B1 (pt) 2017-04-18
KR20070110482A (ko) 2007-11-19
BRPI0516993A (pt) 2008-09-30
CN101044017A (zh) 2007-09-26
US20060089068A1 (en) 2006-04-27
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