CN101198462B - 挠曲刚性复合片材 - Google Patents

挠曲刚性复合片材 Download PDF

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CN101198462B
CN101198462B CN2006800211487A CN200680021148A CN101198462B CN 101198462 B CN101198462 B CN 101198462B CN 2006800211487 A CN2006800211487 A CN 2006800211487A CN 200680021148 A CN200680021148 A CN 200680021148A CN 101198462 B CN101198462 B CN 101198462B
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composite sheet
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glass
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卡尔-路德维格·布伦特鲁普
安德烈亚斯·基尔巴赫
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Quadrant Plastic Composites AG
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
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    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
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    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
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    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/504—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands
    • B29C70/506—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands and impregnating by melting a solid material, e.g. sheet, powder, fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
    • B29K2309/08—Glass
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    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
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Abstract

本发明涉及挠曲刚性复合片材，其具有空气空隙含量小于5体积％的玻璃纤维增强聚丙烯的一个或两个外层A以及空气空隙含量为20-80体积％的玻璃纤维增强聚丙烯的芯层。

Description

挠曲刚性复合片材
技术领域
本发明涉及挠曲刚性复合片材，其包括一个或两个玻璃纤维增强聚丙烯外层和含有空气空隙的玻璃纤维增强聚丙烯芯层。
背景技术
玻璃纤维增强聚丙烯的热塑性可模压半成品片材，即所谓的GMT片材正越来越多地用于模制品，尤其是汽车部件模制品的生产。它们通过以下方法以工业规模进行生产：在双带压力机(double band press)中将玻璃毡片材与聚丙烯熔融片材熔合，并且在远高于1bar的压力下将其压在一起。通常具有0.5-3mm厚度的这种“塑料片材”具有高韧性和坚固性的特点。
已公开的德国专利申请DE-A 19520477公开了纤维增强GMT片材，其在受热时由于玻璃毡的回复力而发泡，并且其包含无规分布的空气空隙。这种发泡GMT片材可以认为是支承芯，并且与未发泡GMT箔(foil)压在一起。实施例1描述了玻璃纤维含量仅30wt％的发泡片材。
发明内容
对于多种应用目的，尤其是用于建筑工业中的大面积部件，缺点是GMT片材非常薄，并且不是挠曲刚性的。因此，本发明的目的在于提供足够稳定却轻质的挠曲刚性复合片材。
本发明的主题为挠曲刚性复合片材，其包括：
A.由玻璃纤维增强聚丙烯制成的、玻璃含量为20-60重量％且空气空隙含量小于5体积％的厚度为0.5-5mm的一个或两个外层，以及
B.由玻璃纤维增强聚丙烯制成的、玻璃含量为35-80重量％且空气空隙含量为20-80体积％的厚度为2-40mm的芯层，
其中，该芯层已经通过以下方法获得：干混合聚丙烯纤维和玻璃纤维，针刺该混合的无纺布，并且进行热压。
根据本发明的复合片材，其特征在于层A中的玻璃纤维以如下形式存在：具有10-100mm的重量平均长度的无向纤维的针刺毡，或者用无向纤维针刺的机织布或无纺布。
根据本发明的复合片材，其特征在于层B中的玻璃纤维为针刺在一起的具有10-60mm的重量平均长度的无向纤维。
根据本发明的复合片材，具有层顺序A-B-A。
根据本发明的复合片材，其特征在于在其一侧或两侧设有各功能层，例如箔、机织纺织物或纤维无纺布。
本发明还提供制备所述复合片材的方法，其特征在于在压力机中，在180-220℃的温度下，将各单独的层压在一起5-50分钟。
根据本发明的方法，其特征在于芯层B由各自具有1-10mm厚度的数个单独的层层叠在彼此之上构成。
具体实施方式
对于层A，通常采用具有0.5-5mm、优选1-3mm厚度的常规GMT片材。这些包含20-60重量％、优选25-50重量％的玻璃纤维。热塑性基体为聚丙烯，其优选具有范围为20-150g/10min的根据DIN 53735的MFI(230℃，2.16kp)。该玻璃纤维优选是无向的(nondirectional)，并且具有10-100mm、尤其是20-50mm的重量平均长度。然而，也可以使用玻璃纤维机织布或无纺布与数层无向纤维的结合生产该片材。在任何情况下，该纤维均是在使用聚丙烯熔体浸泡之前进行针刺，因此纤维毡得以巩固，并且纤维在某种程度上断裂。由于该生产方法包括在双带压力机上加压，并且同时冷却，因此该GMT片材含有小于5体积％、优选小于2体积％的空气空隙，尤其，根本没有空气空隙。
芯层B由玻璃含量为35-80重量％、优选40-70重量％的玻璃纤维增强聚丙烯构成。该纤维优选是无向的而且优选是针刺的，但是由于无纺布的形成及其针刺，一些纤维还排列在Z方向上。根据本发明，必需的是芯层含有空气空隙，即20-80体积％，优选25-75体积％。成品复合材料中的芯层具有2-40mm、优选3-30mm的厚度。通过以下方法根据本发明生产用于芯层的片材：干混合热塑性纤维和玻璃纤维，针刺该混合的无纺布，加热至高于聚丙烯的软化点的温度并压制在一起。优选地，该压制在双带压力机上连续进行，尤其通过热压和冷压工具连续进行，在各工具中，混合的无纺布在小于0.8bar的压力下压制至少3秒钟。这种方法已经提出。在混合各纤维之后，例如根据梳理或气流成网工艺，展开玻璃纤维束，以便使纤维呈现为单独的长丝。结果是在混合无纺布的热压过程中，残留在芯层中的空气空隙规则地分布，因此导致与发泡的GMT片材相比具有改善的机械性能。
有利地，本发明的复合片材通过以下方法制备：将单独的层A和B不连续地堆叠在彼此之上，并且在0.1-1bar的压力下，在180-220℃，优选190-210℃的温度下，在压力机中压在一起5-50分钟，优选10-30分钟，这些层的顺序优选为A-B-A。
由于使用上述生产方法仅能将含有空气空隙的片材制成厚度最大10mm的事实，因此在需要生产较厚的复合片材的情况下，在压制过程中，将几个这种含有空气空隙的片材堆叠在彼此之上。当生产该复合片材时，其表面可以通过同时在各功能层上压制来进行精制，所述各功能层例如箔(可以任选着色)、纺织机织布或薄的无纺布。还可以向表面压入矿物颗粒。
可以为纤维增强外层提供功能层，例如聚丙烯箔，以用于密封、改善光学性能、促进粘合等。
可以将机织布、无纺布以及其它形式的定向增强物包埋至外部的层中，以使整个夹层结构的复合物具有极端的刚度。
与常规GMT片材A相比，本发明的复合片材具有以下优点：其是挠曲刚性的并且适合于插入钉子和螺钉。与没有外层的含有空气空隙的片材B相比，它们具有以下优点：具有光滑、耐磨和防水的表面，而且具有更好的刚度。
与包含具有泡沫或蜂窝结构的芯层以及GMT外层的已知复合片材相比，本发明的复合片材具有以下优点：更好的推挤(pushing)和剪切强度。
该复合片材的主要应用领域为建筑物的隔墙和隔板元件，还作为刨花板和胶合板的替代品用于家具的制造。

Claims (8)

1.挠曲刚性复合片材，包括
A.由玻璃纤维增强聚丙烯制成的、玻璃含量为20-60重量％且空气空隙含量小于5体积％的、厚度为0.5-5mm的一个或两个外层，以及
B.由玻璃纤维增强聚丙烯制成的、玻璃含量为35-80重量％且空气空隙含量为20-80体积％的、厚度为2-40mm的芯层，
其特征在于该芯层通过以下方法获得：干混合聚丙烯纤维和玻璃纤维，针刺混合的无纺布，并且进行热压。
2.根据权利要求1的复合片材，其特征在于层A中的玻璃纤维以如下形式存在：具有10-100mm的重量平均长度的无向纤维的针刺毡，或者用无向纤维针刺的机织布或无纺布。
3.根据权利要求1的复合片材，其特征在于层B中的玻璃纤维为针刺在一起的具有10-60mm的重量平均长度的无向纤维。
4.根据权利要求1的复合片材，具有层顺序A-B-A。
5.根据权利要求1的复合片材，其特征在于在其一侧或两侧设有各功能层。
6.根据权利要求5的复合片材，其特征在于在其一侧或两侧设有箔、机织纺织物或纤维无纺布。
7.制备根据权利要求1的复合片材的方法，其特征在于在压力机中，在180-220℃的温度下，将各单独的层压在一起5-50分钟。
8.根据权利要求7的方法，其特征在于芯层B由各自具有1-10mm厚度的数个单独的层层叠在彼此之上构成。
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