CN101838473B - 热塑性地可变形的纤维增强半成品 - Google Patents

热塑性地可变形的纤维增强半成品 Download PDF

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CN101838473B
CN101838473B CN201010142929XA CN201010142929A CN101838473B CN 101838473 B CN101838473 B CN 101838473B CN 201010142929X A CN201010142929X A CN 201010142929XA CN 201010142929 A CN201010142929 A CN 201010142929A CN 101838473 B CN101838473 B CN 101838473B
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卡尔-路德维格·布伦特拉普
哈里·迪特马
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Quadrant Plastic Composites AG
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Abstract

本发明涉及热塑性地可变形的纤维增强半成品，其由热塑性材料和增强纤维组成，该增强纤维具有25到50mm的平均长度，该半成品具有35到65体积％的气孔含量，其中该增强纤维彼此互相进行针刺，它们中超过80％的是以单丝的形式来存在的。

Description

热塑性地可变形的纤维增强半成品
本分案申请是申请日为2006年4月4日、中请号为200680019964.4、发明名称为“生产热塑性地可变形的纤维增强半成品的方法”的发明专利中请的分案申请。
技术领域
本发明涉及热塑性地可变形的纤维增强半成品。
背景技术
包含增强纤维(特别是玻璃纤维)的热塑性地可变形的半成品，越来越广泛地应用于模制品(特别是汽车零件)的生产。这样的“塑料板”的特征在于高强度和韧性。GMT半成品通过将连续的玻璃纤维束(strand)毡和熔融热塑性膜在双带压力机中结合来进行大规模的工业化制造。这一工艺消耗显著量的能量，因为粘性熔体必须在远高于1巴的压力下压成毡子。因此实践上通过这一方法来达到纤维含量大于45wt％和单位面积重量(areal weight)在2000g/m2以下是格外困难的。因为玻璃毡子一般由纤维束或“股(strand)”制成，所以使用热塑性物质的浸渍从来没有彻底完成和均匀，并且因而存在微小的不均匀区，从而造成在机械性能上的高的标准偏差。这也是使用热膨胀的GMT平板的情况，由于针刺(needle)在一起的玻璃纤维的回复力，其包含气孔，然而，该气孔在基体之内是不规则地进行分布的。
DE-A3614533描述了生产包含增强嵌入物的热塑性塑料的模塑制品的方法。根据纺织品纤维技术，热塑性纤维和增强纤维的混纺的无纺织物由梳理法或空气压条(air-laying)法来生产，并且其通过如针刺来加固(consolidate)。将这一混纺的无纺织物的裁减部分进行加热并且在没有预先加固的情况下直接压制成三维模制品。完全浸渍是非常难以获得的，特别是对于具有复杂形状的组件的情况下，因此模制品的机械性能还有许多待改进之处。
根据WO98/3508，在一种复杂的方法中，首先生产增强纤维和热塑性纤维的混纺的束，然后由它们来生产无纺织物。此无纺织物在双带压力机上在高温和高压下进行压制来形成半成品。
WO02/062563描述了由热塑性物质和由长的增强纤维来生产热塑性地可变形的薄的半成品的连续方法。该方法包括以下步骤：
A.对热塑性纤维和增强纤维进行干混纺(blending)以形成混纺的无纺织物(blended nonwoven)，
B.通过针刺来使得该无纺织的混纺物致密化，
C.加热该致密化的混纺的无纺织物，以及
D.在压延机或压力设备上进行压制以形成半成品，
E.任选地压制到各功能层(functional layers)上。
WO02/076711描述了生产厚的混纺的无纺织物的相似方法，其中在步骤D中的压制也能在层压设备上以1-10巴的压力实施。然而所发现的是：在这样的高压下，气孔几乎完全地从该柔软的混纺的无纺织物中被压出来，并且熔体在长度和宽度上分开流动，这造成在单位面积重量上的不受控制的变化，并且造成半成品的变形，其结果是：半成品的边界是波形的而不是光滑的和直的。
相似的问题在根据EP-B593716和US-A4,978,489的方法中出现，其中，混纺的无纺织物通过彼此面对的压辊来进行压缩模制。在此方法中，对该毡子进行强烈地压紧使得所得的半成品只包含最大20体积％和优选10-15体积％的气孔。在根据US-A4,948,661的方法中，混纺的无纺织物在加热的压板或双带压力机之间进行压紧，直到空气从该加固的产物中完全地被消除为止。
在压延机中或由压辊所进行的混纺的无纺织物的压紧具有另外的缺点：仅能使用低生产速度，并且由在辊之间的间隙中的突然的压缩导致形成凸起，其会导致强的扭曲，甚至形成孔。
WO03/086725描述了制造纤维增强的复合材料的装置和方法。在此方法中，对热塑性纤维和增强纤维的针刺的混纺的无纺织物毡子进行加热和如在连续的带状压力机中进行模制。没有关于必需使用的压力的可靠信息。尽管其阐明了能形成“仿泡沫复合材料片材”，但是没有关于气孔含量的信息。而且，该复合材料将有超过60wt％的热塑性纤维含量。
发明内容
本发明包括：
1.本发明第1项，提供一种生产包含10到80wt％热塑性材料和90到20wt％增强纤维的热塑性地可变形的半成品的连续方法，该方法包括以下步骤：
A.对热塑性纤维和单独的未束缚的增强纤维进行混纺以形成未切的(cndless)毡，
B.所得的混纺的无纺织物通过热处理或通过针刺以致密化，
C.加热该致密的混纺的无纺织物至该热塑性纤维的软化点以上的温度，
D.对该加热的混纺的无纺织物进行压紧以形成半成品，
其特征在于：该压紧在加热的压制工具和在冷却的压制工具上相继地进行，其中该混纺的无纺织物在低于0.8巴的压力下至少压缩3秒。
2.根据本发明第1项的方法，其特征在于，在进行步骤D的压紧的同时将各功能层压制到该加热的混纺的无纺织物上。
3.根据本发明第1项的方法，其特征在于：该热塑性纤维和该增强纤维的重量平均长度是20到120mm，这两类纤维在长度上的差异优选不超过25％。
4.根据本发明第1项的方法，其特征在于：在压制过程中，在该压制工具中，施加0.05-0.5巴的压力，并且在该加热的压制工具中的停留时间是5到60秒，以使所得的半成品的气孔含量为25-75体积％，优选为35-65体积％。
5.根据本发明第1项的方法，其特征在于：该压制工具包括压板，对织物带进行回转，该织物带沿着该压板滑动并传输该混纺的无纺织物。
6.根据本发明第1项的方法，其特征在于：在该加热的压制工具中的温度大于80℃，优选为100-220℃；并且在该冷却的压制工具中的温度低于30℃，优选为15-25℃。
7.根据本发明第1项的方法，其特征在于：在步骤D的过程中，在该加热的压制工具之前，具有进一步安排的加热的辊对；并且在该压制工具的加热区域之后，具有进一步安排的冷却的辊对。
8.根据本发明第7项的方法，其特征在于：低于10N/mm的线压力施加在该加热的辊对中。
9.根据本发明第7项的方法，其特征在于：10到50N/mm的线压力施加在该冷却的辊对中。
10.热塑性地可变形的半成品，其包含25到55wt％的热塑性材料和75到45wt％的增强纤维，该增强纤维具有25-50mm的重量平均长度且该半成品具有35-65体积％的气孔含量，该气孔均匀地在基质中进行分布，其特征在于：该增强纤维彼此互相进行针刺，且超过80％的该增强纤维以单丝存在。
11.根据本发明第10项的热塑性地可变形的半成品，其特征在于：其由25-55wt％的聚丙烯和75-45wt％的玻璃纤维组成，且其单位面积重量为250-1800g/m2。
因此，本发明的目标是提供生产热塑性材料和增强纤维的无变形的半成品的一种简单而又连续的方法，该半成品包含具有均匀分布的气孔并且可以容易地改变该半成品的形状，以便提供在所有方向都有优秀和高度地可再现的性能的成品零件。
此目标由本发明的方法来完成。本发明的方法包括以下步骤：
A.热塑性纤维和单个的、未粘结的增强纤维一起混纺。合适的热塑性物质包括所有可纺丝的热塑性物质，如聚烯烃例如聚乙烯和聚丙烯、聚酰胺、线性聚酯、热塑性聚氨酯、聚碳酸酯、聚缩醛和对应的共聚物与热塑性物质的共混物，以及具有高热稳定性的聚合物例如聚芳酯、聚砜、聚酰亚胺、聚醚酰亚胺和聚醚酮。特别优选的是根据DIN 53735的MFI(230℃，2.16kg)大于20g/10分钟、特别在25和150g/10分钟之间的聚丙烯。热塑性纤维一般具有的平均长度(重量平均)是20mm到120mm。
优选的增强纤维是玻璃纤维，但碳纤维、玄武岩纤维和芳族聚酰胺纤维也可以被使用。此外，天然纤维(如由亚麻、黄麻、大麻、洋麻、剑麻和棉花所制成的那些)也是有用的。特别关心的是玄武岩纤维，与玻璃纤维相比而言，其在对纤维增强的成品零件进行热处理之时不会熔化和不会形成炉渣。相对昂贵的玄武岩纤维优选地按照10∶90到50∶50的重量比与天然纤维进行混合。一般，增强纤维具有的平均长度(重量平均)是20mm到120mm。为了能与热塑性纤维容易地进行混纺，它们必须基本上是单个的未粘结的纤维的形式，即，它们不能保持与聚合物粘结剂粘合在一起的状态。
在本发明的优选实施方案中，热塑性纤维的平均长度和增强纤维的平均长度的差最大是25％，优选最大是10％并且特别地最大是3％。优选的玻璃纤维可作为未切(endless)纤维或作为切割纤维来购买，其长度是0.5英寸(12.7mm)。另外，长度为例如1英寸(25.4mm)或2英寸(50.8mm)的切割纤维也是可利用的。实践上，将热塑性纤维切成与玻璃纤维的长度大约一样，即，在本发明的特别优选的实施方案中，所使用的聚丙烯纤维和玻璃纤维都有大约相同的长度并且所具有的平均长度(重量平均)都是在25mm到55mm范围之内。
纤维长度的这种匹配有以下优点，在半成品的生产过程中，不发生纤维的反混合(demixing)，该反混合在半成品中导致不均匀性，即导致富-玻璃区和富-聚合物区。这是特别重要的，如果纤维通过空气压条(airlay)法来进行混纺。
所使用的热塑性纤维和增强纤维的重量比是10∶90到80∶20，优选20∶80到65∶35，且更特别为25∶75到55∶45。在该混纺的方法中，玻璃纤维应该是相对地干燥的，这意味着它们的水含量应该是低于6wt％，优选为0.5到4wt％。该混纺可以根据空气压条法或梳理法来进行。这些方法在纺织品技术中是公知的。所发现的是：在梳理法过程中，纤维还能包含更大量的水，如最高至15％。混纺所生产的无纺织的连续带所具有的单位面积重量是200到2500g/m2，特别是从250到1800g/m2。在混合纤维之时，以大的程度或完全地打开玻璃纤维束，使得多数或所有玻璃纤维是作为单丝而存在。
B.然后，对由此获得的混纺的无纺织物进行加固，优选通过在一面或双面进行针刺来加固。这可以在常规针刺机上用刺针来完成。针刺导致增强纤维的一些破损，从而减少了平均纤维长度；另一方面，针刺加固了混纺的无纺织物，从而使其在随后的方法的步骤中可以没有问题地进行处理。而且，针刺在Z轴方向上导致增强纤维的部份取向，由此能够控制膨胀(loft)(在重新加热时所压紧的半成品的恢复)。作为在Z方向上的增强纤维的此取向的进一步的结果，由本发明半成品所形成的成品在此方向上也被增强。原则上，通过热途径(如由IR辐射或通过热空气)进行加固也是可能的。然而，在这种情况下，热塑性纤维不应该完全地熔化，而是只进行表面熔化到以下的程度：半成品将有充足的内聚以便于进行处理和输送。
C.然后，将该已加固的混纺的无纺织物加热到在热塑性物质的软化温度之上的温度，优选在连续的烘箱中或通过IR辐射来进行。该在软化温度之上的温度优选应该是20℃到60℃；在聚丙烯纤维的情况下，温度优选是在180℃和220℃之间，特别地在190℃和210℃之间。与使用多数玻璃纤维束没有被打开成单丝的上述GMT方法相比而言，热塑性的熔体能容易地“浸渍”单丝，且其获得基本上更好且更加均匀的玻璃纤维的浸渍。GMT方法导致例如由GMT半成品生产的成品的性能的差的均匀性。
D.在加热之后，立即对所加热的混纺的无纺织物进行压紧。根据本发明，相继使用加热的压紧工具和冷却的压紧工具，其中，混纺的无纺织物以低于0.8巴的压力，优选0.05到0.5巴进行至少3秒的压紧。在加热的压制工具中，停留时间优选是在5和60秒之间，而在冷却的压制工具中，停留时间可大于几分钟。0.8巴的上限是重要的；在更高的压力下，气孔含量变得太低。优选，在所使用的压板上，两条回转的织物带(其如由涂覆着特氟隆的玻璃或芳族聚酰胺织品制成)沿着压板滑过，并且从而传输该混纺的无纺织物。该加热的压制工具优选加热到高于80℃，尤其到100℃-220℃，并且该冷却的压制工具优选地保持在低于30℃，并且尤其在15℃-25℃。
优选，在步骤D中，在该加热的压制工具的上游另外设置加热的辊对(rollpair)，并且在该加热的压制工具的下游另外设置冷却的辊对。
该加热的辊对主要用来提供功能层和用于将各功能层施加在该加热的混纺的无纺织物上。对于该目的来说，低于10N/mm的低线型(或“线”)压力是足够的。压制工具(其特别加热到150℃到200℃)导致将增强纤维被压进热塑性物质的熔体中，并且将增强纤维湿润到充足的程度，而且其也导致一些空气被挤出。该冷却的辊对以优选10到50N/mm的线型压力，将各功能层紧紧地压到该部份加固的半成品上，使得一个或多个功能层被结合到其上。此外，如果需要，能设置冷却的辊对，来导致在厚度上的进一步的减少。该热塑性物质的熔体通过冷却的压制工具来完全地固化，使得回复力能够不再起作用，所有功能层牢固地熔合到产品上，从而加固了半成品。
压制的操作在这样的温和条件下来进行，使得所得的半成品仍然有在25和75体积％之间、尤其是35到65体积％的气孔(“空隙”)含量。由于此事实，与压紧或几乎压紧的半成品相比而言，此产物能够更加容易地进行处理，如通过在压制工具中进行热成形来处理。由于玻璃纤维与热塑性基质的上述均匀的浸渍，气孔在半成品中均匀地分布。这与膨胀的(expanded)GMT对比而言，其具有气孔的不规则的分布并且其包含未打开的玻璃纤维束和基质聚集体。
如果需要，在压制的操作下将各功能层与加热的混纺的无纺织物的一面或双面同时地进行接触并且它们被共同地压紧。这些另外的层可以是装饰层、薄纤维无纺织物、热塑性膜或者织物片。
所得的平的半成品优选具有的厚度是0.5mm到10mm，尤其是从1.0到5.0mm。对于特别的应用而言，厚度可以共计甚至超过5.0mm。在半成品中的增强纤维的平均长度(重量平均)是20mm到120mm，优选是25mm到100mm，并且尤其是25mm到50mm。
本发明的另外的目标是提供一种热塑性地可变形的半成品，其中热塑性材料是25到55wt％，并且增强纤维是75到45wt％，增强纤维的重量平均长度(an average length by weight)是25mm到50mm，该半成品包含35到65体积％、优选45到55体积％的均匀分布的气孔，其中，增强纤维彼此互相进行针刺，并且超过80％(优选超过90％)的增强纤维以单丝存在。半成品优选具有的单位面积重量是250到1800g/m2，并且优选包含25wt％到55wt％的聚丙烯和相应的75wt％到45wt％的玻璃纤维。
DE-A19520477公开了热膨胀的纤维增强的片或板，且因此包含气孔。如以下进一步所描述的，这些气孔在板中是非常不规则地分布的，而在本发明的半成品中的气孔是均匀地分布的。而且，在膨胀的GMT板材中，玻璃纤维主要作为未打开的纤维束而存在。在两种情况下的区别在扫描电子显微(SEM-)照片中能容易地被发现。实施例1显示了一种单位面积重量是远大于2000g/m2的膨胀的板。玻璃纤维的长度是100mm，并且玻璃纤维的含量是30wt％。
US-A2004/0112501公开了可变形的半成品，其通过在1-10巴之间的压力下对包含热塑性纤维和增强纤维的混纺的无纺织物进行加热和加压来制备。然而，在如此高的压力下，气孔几乎完全地从该柔软的混纺的无纺织物中被压出，使得在半成品中的气孔含量远低于35体积％。
EP-A-758577公开了可变形的层状的半成品，其由“造纸”方法所制备，其中，短切束(chopped strand)与热塑性物质的微粒在乳化剂的水溶液中进行分散，然后压紧、干燥并且进行热压。所得的板材按照多孔半成品的1.1到15倍来进行热膨胀。在半成品中的玻璃纤维没有进行针刺，没有提及“单丝”。由于缺乏针刺，它们未产生破损，而是有均匀的长度，而且，它们全部在二维平面上进行定位。这导致由这样的半成品生产的成品的不足的机械性能。
EP-A888856公开了短切的塑料废物，如热塑性物质和天然纤维的混合物；其能具有的密度是100到1000kg/m3。
根据本发明所生产的半成品可以卷起并存放或者立刻切成板材，如具有尺寸400到3000mmx300到2300mm。可以对它进行热塑性处理来形成三维成品零件。为了完成上述目的，首先将适当地切割的部分加热至该热塑性物质的软化温度以上，然后进行再成形。在这样做时，半成品由于被针刺的纤维无纺织物的回复力而膨胀；气孔含量越大，膨胀越大。例如，相比于致密的板材而言，膨胀至其原始厚度的两倍以上、优选三倍以上的半成品在热成形过程中能够容易得多地进行再成形。在再成形过程中，半成品通过常规的两箱铸型(two-part molds)来进行压制或其由深冲压来进行成形。
成品零件能作为汽车、铁路和航空器零件来用于交通运输部门，而且能作为车身零件，或作为大面积面板和家具零件。另外，它们可以用作声学部件，并且其在夹心层压材料中可以用作覆盖层以用于壳体元件或隔板。
附图说明
图1显示了半成品样品剖面图的放大了32倍的入射光学显微图片。
图2显示了通过半成品样品的抛光部分的放大了200倍的SEM图。
图3显示了半成品样品的抛光部分的放大了32倍的入射光学显微图片。
图4显示了通过半成品样品的截面的放大了200倍的SEM图。
具体实施方式
实施例1
熔体流动指数(230℃，2.16kg)为25g/10分钟且长度是大约40mm的聚丙烯切断纤维与长度为50.8mm且水含量是大约1％的短切玻璃纤维一起混合，然后均匀地进行混合，并且在连续的空气压条方法中成丝。聚丙烯纤维和玻璃纤维的重量比是60∶40。具有1200g/m2单位面积重量的所得的无纺织物纤维网(nonwoven fleece)在常规针刺机上从一面进行针刺。将宽度略超过2m的预压紧的纤维网在气流烘箱中加热到约190℃来熔化聚丙烯，之后立刻转移到加热的双带层压机上。在那里，其在0.5巴的压力下压紧大约15秒。层压机温度是约150℃，这是为了将纤维网的芯的温度保持在聚丙烯的软化点之上，并且为了使其均匀地穿过(penetrate)玻璃纤维。另一方面，由于相对地低压，该三维任意地取向的玻璃纤维部份地抵消了压力，从而使得空气空隙的某一部分在纤维网之内被保留下来。随后，将纤维网引入到冷的(保持在20℃)双带层压机中，将其在双带层压机中在0.2巴的压力下保持90秒，从而固化聚丙烯。
将厚度是2.3mm的所得的半成品切成大小是2mx2m的坯件。平均玻璃纤维长度略低于50mm。在充分加固(consolidation)的情况下，厚度将是1.0mm。因此，所计算的空隙含量是55体积％。图1显示了半成品样品剖面图的放大了32倍的入射光学显微图片。能看到相当均质的空隙分布。图2显示了通过半成品样品的抛光部分的放大了200倍的SEM图。单根纤维的高度成丝作用(超过90％)能被看见。板材具有高刚度，没有变形且其容易处理和运输，如由机器人处理设备来进行处理和运输。
比较例2
重复进行实施例1，除了以下不同之外：压制在加热的双带层压机中在3巴的压力下进行90秒，并且在冷却的双带层压机中在2巴下进行100秒。所得的半成品仅有1.1mm的厚度。相应地，所计算的空隙含量仅为9体积％。由于高压，薄膜和稀松布(scrim)都不能一起被压紧。结果，薄致密板材的处理和运输是困难的。
比较例3
将与实施例1中的无纺织物纤维网相同的无纺织物纤维网切成250mm宽的卷，以适应鼓轮尺寸为200x300mm的实验室级的压延机的宽度。纤维网通过将其穿过气流烘箱来加热到180℃，然后将其引入压延机的狭缝中。将二个辊的表面温度调整到40℃，线形压力是300N/mm，并且转速是5m/分钟。压过的纤维网显示了由高压造成的100％的伸长，并且其由于极度的形状变形和纤维取向而不能被使用。
在进一步的试验中，线性负荷减少到50N/mm，并且转速减少到2m/分钟。由于极度的形状变形和纤维取向，该压紧的纤维网也不能使用。
进行另外的试验，其中变化了温度、压力和转速。然而，生产没有形状变形和没有内部张力的板材是不可能的。
比较例4
基于根据DE-A19520477的实施例1的GMT方法，两个针刺的玻璃纤维毡(它们的单位面积重量都是1240g/m2且玻璃纤维长度都是100mm)用聚丙烯熔体(单位面积重量是2860g/m2)在双带压力机的加热的区域中在3巴的压力下来进行浸渍。在以下冷却区中，层压制品用在钢带和基板之间的几乎无压力的接触来进行冷却。这造成玻璃纤维毡与已经熔化的聚丙烯在钢带之间一起膨胀。将多孔层压制品的表面温度减少到110℃之下，使得层压制品容易地去除。所得的膨胀的GMT半成品有30wt％的玻璃纤维含量；并且其密度是0.6g/cm3，对应于50体积％的气孔含量。对于作为轻型组件的应用或汽车内部零件来说，4100g/m2的单位面积重量是太高了。图3显示了半成品样品的抛光部分的放大了32倍的入射光学显微图片。与图1比较而言，存在基本上更多的不均匀分布的气孔。图4显示了通过半成品样品的截面的放大了200倍的SEM图。能够看出，纤维束仅仅很少地被打开。

Claims (2)

1.热塑性地可变形的半成品，其包含25到55wt％的可纺丝的热塑性材料和75到45wt％的增强纤维，该增强纤维选自玻璃纤维、碳纤维、玄武岩纤维、芳族聚酰胺纤维和天然纤维且具有25-50mm的重量平均长度且该半成品具有35-65体积％的气孔含量，该气孔均匀地在基质中进行分布，其特征在于：该增强纤维彼此互相进行针刺，且超过80％的该增强纤维以单丝存在。
2.根据权利要求1的热塑性地可变形的半成品，其特征在于：其由25-55wt％的聚丙烯和75-45wt％的玻璃纤维组成，且其单位面积重量为250-1800g/m2。
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ES2318720T3 (es) 2009-05-01
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US20120181716A1 (en) 2012-07-19
CN101838473A (zh) 2010-09-22
US8540830B2 (en) 2013-09-24
CN101189117A (zh) 2008-05-28
KR101348269B1 (ko) 2014-01-08
US20060244170A1 (en) 2006-11-02
EP1868796A1 (de) 2007-12-26
JP5215841B2 (ja) 2013-06-19
EP1868796B1 (de) 2009-01-28
US20100116407A1 (en) 2010-05-13
DE502006002749D1 (de) 2009-03-19
ATE421920T1 (de) 2009-02-15
JP2008534813A (ja) 2008-08-28

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