CN102015235B - 用于制造合成材料片材的方法和设备 - Google Patents

用于制造合成材料片材的方法和设备 Download PDF

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CN102015235B
CN102015235B CN200980110730.4A CN200980110730A CN102015235B CN 102015235 B CN102015235 B CN 102015235B CN 200980110730 A CN200980110730 A CN 200980110730A CN 102015235 B CN102015235 B CN 102015235B
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knitmesh
station
volume
equipment
synthetic material
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CN102015235A (zh
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爱德华·皮尔佩尔
B·D·皮尔佩尔
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Avient Corp
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Gordon Holdings Inc
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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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5042—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like covering both elements to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/435—Making large sheets by joining smaller ones or strips together
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72141—Fibres of continuous length
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
    • B29C66/83413—Roller, cylinder or drum types cooperating rollers, cylinders or drums
    • 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
    • B29C70/28—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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F41H5/0471—Layered armour containing fibre- or fabric-reinforced layers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F41H5/0471—Layered armour containing fibre- or fabric-reinforced layers
    • F41H5/0485—Layered armour containing fibre- or fabric-reinforced layers all the layers being only fibre- or fabric-reinforced layers
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72143—Fibres of discontinuous lengths
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/822—Transmission mechanisms
    • B29C66/8223—Worm or spindle mechanisms
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/824—Actuating mechanisms
    • B29C66/8242—Pneumatic or hydraulic drives
    • 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
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B29C70/202—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC]
    • 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
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/721—Vibration dampening equipment, e.g. shock absorbers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means
    • Y10T156/1702—For plural parts or plural areas of single part
    • Y10T156/1712—Indefinite or running length work
    • Y10T156/1715—Means joining indefinite length work edge to edge
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means
    • Y10T156/1702—For plural parts or plural areas of single part
    • Y10T156/1712—Indefinite or running length work
    • Y10T156/1741—Progressive continuous bonding press [e.g., roll couples]

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Ceramic Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

通过将合成材料的合成原料彼此相邻(边对边)布置可以制造合成材料的制品片材。合成原料包括热塑性基体材料中的纤维。相邻的合成原料粘接在一起来提供合成材料的制品片材。优选地，在合成原料上布置合成材料的交叉层。交叉层可以是单向片材并且可以与合成原料中的纤维成横切关系来布置交叉层中的纤维。

Description

用于制造合成材料片材的方法和设备
相关申请的交叉引用
本申请要求2008年3月26日提交的美国临时申请61/039,556的优先权，通过引用将其全部内容并入本文。
技术领域
本发明涉及用于制造包括合成层板材料的合成材料片材的方法。
背景技术
包含热塑树脂基体中的纤维的合成原料片材在合成层板制造中作为板层。纤维布置在聚合基体材料中以形成合成片材。本领域已知各种方法，通过这些方法可以把合成材料片材中的纤维布置在聚合基体材料中并且通过包括例如刮刀处理、层叠、挤拉、挤压成型等方式被压缩。纤维可以纵向定位(即，它们彼此对齐)并且在沿着板层的长度方向上是连续的。纤维板可以切削并且相对于彼此纵向定位。参考这里的纤维的均匀纵向定位，合成材料片材可以被表征为“单向”。
合成材料片材的宽度典型地受限于如控制纤维分发时的难度以及通常使用的加工机械的宽度等因素。另外，合成层板包括多个板层，在彼此上下堆叠时，板层可以使得不同板层中的纤维具有相对于彼此不同的角度方位。通常，通过将合成材料的各个板层与彼此呈交叉关系的纤维堆叠，并且将堆叠粘合成单个片材，来在分立处理中组装合成层板。
发明内容
本发明的一方面涉及一种用于制造合成层板的设备。该设备包括第一展开工位，其包括至少一个卷支撑组件，用于旋转支撑合成材料卷。粘合工位位于所述第一展开工位的下游并且限定粘合表面。加热工位位于粘合工位的下游，用于响应于移动通过加热工位的合成材料来加热从卷馈送的合成材料。该设备还包括处理工位，其包括位于加热工位下游的至少一个压延卷组件。
本发明的另一方面涉及一种用于通过定位彼此相邻的多个不同长度的合成材料来制造合成层板的方法。把不同长度的合成材料粘合在一起并且加热不同长度的合成材料。把经过加热的不同长度的合成材料传输通过压延卷组件从而生成合成层板；并且收集合成层板。
附图说明
图1是用于应用本文中根据本发明的实施例描述的制造方法的设备的示意图；
图2A是图1中的设备的展开工位的一个实施例的透视图；
图2B是图2A中的展开工位的支撑辊组件的透视图；
图2C是图2A中的展开工位的材料导向组件的透视图；
图3是具有图1中的设备中的可选第二板层工位的粘合工位的透视图；
图3A是图3中的具有第一板层合成原料和用于在其上粘合的交叉合成材料的粘合工位的透视图；
图4是在图1中的设备中的烘烤工位的示意性透视图；
图5A是图1中的设备的一个或多个处理模块的正视图；
图5B是图5A中的一个或多个处理模块的加热压延卷组件的透视图；
图5C是用于图5B的一个或多个处理模块的加热压延卷组件的卷烤炉的分解透视图；
图5D是图5A中的一个或多个处理模块的冷却压延卷组件的透视图；
图6是图1中的设备的收起工位的透视图；以及
图7是根据一个实施例的方法的流程图。
具体实施方式
图1中的10总体上示出的是用于制造合成材料的设备的一个实施例，该设备包括展开工位12，其中合成材料可以馈送或者从合成材料卷中展开以被设备10进一步处理。相邻展开工位具有粘合工位14，合成材料的附加层可以粘合到从展开工位12展开的合成材料上。这些附加层可以被配置成使得形成合成材料的附加层部分的纤维能够相对于从展开工位12展开的合成材料中的纤维以不同角度定位。然而，本发明并非限于此，因为形成附加层部分的纤维还可以定位成基本平行于形成从展开工位12展开的合成材料部分的纤维。该设备10包括与粘合工位相邻的可选第二展开工位16，合成材料的至少一个附加层可以从其上的合成材料卷展开。这些层可以展开在从第一展开工位12和在粘合工位14处添加的其他附加层展开的合成材料的顶部。在粘合工位14的下游具有加热工位18，合成材料层被加热使得它们可以彼此接合。在加热工位18的下游还具有处理工位20。处理工位20包括至少一个压延卷组件，这会在下文得到详细说明。收起工位22位于处理工位20的下游，用于将合成材料层板卷绕到其上。合成材料从展开工位12到收起工位22的整个进度在此被称为“处理方向”，如图1中的箭头所示。术语“上游”和“下游”在这里有时候被用来指代相对于处理方向的方向或位置(“下游”指代与处理方向一致的方向)。
如图2A所示，展开工位12包括展开框架24，在上面安装了五个结构类似的卷支撑组件，其中一个表示为26。尽管展开工位12具有五个卷支撑组件26，但是本发明并非限于此，因为在不脱离本发明的广义方面的情况下，少于或多于五个卷支撑组件也可以形成展开工位部分。与图2A所示的其他卷支撑组件相同，卷支撑组件26包括支撑辊组件28(又见图2B)和相关的材料导向组件30(又见图2C)。支撑辊组件28包括可旋转耦接到底座34的支撑辊32，底座安装在展开框架24上。每个支撑辊32被配置成在其上承载合成材料卷，如图2A中的合成材料卷36a、36b、36c所示。固定帽38可拆卸地安装到支撑辊32从而可拆卸地在其上保持合成材料卷。固定帽38可以螺纹旋入支撑辊32，然而，本发明并不限于此，因为固定帽还可以以本发明所属相关领域中的技术人员已知的其他方式保持在支撑辊上。例如，固定帽38可以通过螺栓固定到支撑辊32上或者经由卡环保持到其上。支撑辊组件28可以包括支撑辊驱动机构(未示出)或者支撑辊制动机构(未示出)来加速或阻止合成材料卷36a在支撑辊32上的展开从而在合成材料从卷上展开时改变或调节合成材料中的张力大小。
每个材料导向组件30都包括固定到展开框架24的一对直立的辊支架40、42。每个材料导向组件30还包括插入其中并且可旋转耦接到直立的辊支架40、42的第一辊44，和插入在其中并且也可旋转耦接到直立的辊支架的第二辊46。第一辊44和第二辊46协同来限定它们之间的如48所示的辊隙，从相关的支撑辊组件28馈送的合成材料通过该辊隙。第一辊44通过调节机构50可以相对于直立的辊支架40、42垂直滑动，调节机构50用于改变和/或调节辊隙中合成材料36a上的压力和/或合成材料36a中的张力等，和/或从相关的支撑辊组件28中抽拉合成材料的速度。调节机构50可以采取气压或液压汽缸、滚珠丝杠、步进电动机或其他机械致动器的形式。然而，本发明并非限于此，因为还可以采用本发明所属技术领域的技术人员已知的许多其他调节机构。材料导向组件30用作定位和引导从相关的支撑辊组件28抽拉的合成材料36a等。
每个材料导向组件30均可以包括制动机构(未示出)和/或驱动机构(未示出)。制动机构将向第一辊44的旋转施加阻力，使得在拖拉合成材料36a通过48所示的辊隙时，可以在合成材料36a上保持期望的张力。另一方面，材料导向驱动机构可以驱动第一辊44以有助于合成材料36a通过48所示的辊隙的传输。以此方式，调节机构50可以减轻合成材料36a通过48所示的辊隙前进的阻力。由于合成材料卷36a的旋转惯量在从卷抽拉材料时发生变化，所以在设备10的操作期间可以调节调节机构50从而在合成材料36a中保留适当的张力。
五个卷支撑组件26定位在展开框架24上从而在从每个卷中抽拉不同长度的合成材料36a等时，不同长度的合成材料将通过展开框架24中的织网空隙52并且以边对边排列从展开框架24下方出现从而限定织网54(图2A、图4)，该织网横跨由合成材料卷的数量限定的宽度W，该宽度W比合成材料卷中的任何一个都宽。将在下文详细说明的是，织网54为合成层板200提供了至少一个纵向第一层。
粘合工位14位于展开工位12的下游并且包括安装到粘合框架58上的定位平台56。在所示实施例中的粘合框架58限定了大致等于展开框架24宽度的宽度。粘合平台56限定了基本为平面的粘合表面56a，相邻的不同长度的合成材料36a、36b等布置在粘合表面上并且粘合到一起从而形成合成材料200的第一层，例如通过把合成材料36a、36b等的第一层布置在合成材料的第二层上。取决于合成材料36a等的类型和其中的纤维朝向，合成材料的第二层可以纵向或者交叉或以其他配置粘合。
在一个实施例中，通过把合成材料的交叉层60铺设到合成材料36a、36b等上来把合成材料36a、36b等粘合到一起。交叉层60重叠至少两个相邻的合成材料36a、36b并且优选地延伸横跨织网54的整个宽度W。交叉层60被粘合到合成材料36a、36b等从而形成织网54。可以使用热风枪、超声波焊接工具、粘合剂等在织网54移动通过设备10时完成粘合。粘合是一种把相邻和/或分层的合成材料片材固定到期望位置用以粘接在一起的相对快速而简单的方法。
交叉层60可以是单向片材，即，其中的纤维板可以相互对齐。在特定实施例中，交叉层60中的纤维相对于合成材料36a中的纤维横切布置，这种情况下，交叉层60可以被称为交叉片材并且所得到的合成层板200被称为交叉层板。交叉片材可以相对于合成材料36a、36b等中的纤维成任意角度布置。
交叉层60沿处理方向具有有限宽度60w。在一个实施例中，多个交叉层60在合成材料36a、36b等层上彼此相邻布置从而为合成层板200提供了一致的第二板层。
在一个实施例中，可以使用工业机器人来把交叉层60放置到合成材料36a、36b等上，从而可选地把正交层60粘合到上面。这种机器人可以提供有正交层材料的供给，例如以卷的形式或者作为预切割片材的堆叠提供。可以装备机器人来例如通过从供给卷抽拉各个长度的交叉层材料并且把交叉层材料切割成期望的长度、或者处理预切割片材把交叉层材料放置到织网54上。机器人可以装备有粘合臂，粘合臂包括热风枪、超声速焊接操纵杆、或任何其他适合的粘合装置，并且可以把交叉层材料粘合到织网54并且把合成材料36a、36b等粘合到一起。机器人可以配置成在织网54上以正交方式或者以其他任何期望的角度抽拉或放置正交层材料。
可选的第二展开工位16位于粘合工位14的下游或之上，并且包括卷支撑组件62，可以在卷支撑组件上布置附加的合成材料卷。第二展开工位16通常具有与第一展开工位12相同的结构，使得第二展开工位16能够提供横跨宽度大致等于宽度W的合成材料织网，即，第二展开工位16具有定位成与第一展开工位12的卷支撑组件26等的位置相对应的卷支撑组件62。第二展开工位16配置成允许织网54通过其下方并且允许来自第二展开工位16的其他的纵向合成材料层添加到织网54上。以此方式，第二展开工位16有助于为合成层板200提供第二纵向合成材料层。尽管示出并描述了用于设备10的第二展开工位16，但是本发明并非限于此，在其他实施例中，用于制造合成层板的设备可以不具有第二展开工位。在另外实施例中，用于制造合成层板的设备可以具有多于两个展开工位，使得该设备能够制造具有多于两个纵向合成材料层的合成层板。
如图4所示，加热工位18的一个实施例包括烤炉64，其具有适于接收合成材料的织网54的入口(未示出)，以及允许织网54移动通过烤炉的出口66。烤炉64可以包括对流式烤炉和/或其他任意适合的加热元件，如电辐射加热元件、红外加热元件、电热器、热油加热器、气动力加热器及其组合、以及用于加热织网的其他加热元件。烤炉64具有经由诸如(但不限于)液压或气压汽缸、导螺杆、电动机之类的致动器70在升起位置和降低位置之间移动的盖件68。
处理工位20位于加热工位18的下游。在一个实施例中，如图5A所示，处理工位20包括压延卷组件72和74。每个压延卷组件72、74包括支撑两个压延卷76和78的框架80。每个卷的驱动机构82包括经由驱动带82b耦接到压延卷76或78的驱动电动机82a。尽管示出并描述了带式驱动，但是本发明并不限于此，因为还可以利用其他驱动类型，如直接驱动、或电动机和齿轮减速器组合。压延卷组件72、74中的一个或两个压延卷76和78可以装备有旋转接头，其允许热传输流体(例如，油或水)流动通过卷，从而在使用中根据期望加热或冷却卷。
如图5B所示，经过加热的压延卷组件72包括协同来限定它们之间的辊隙的压延卷76和78、以及两个用以加热压延卷78的卷烤炉84和86。卷烤炉84加热压延卷78的一部分，而提供第二卷烤炉86使得压延卷在整个长度上被加热，然而，本发明并非限于此，在其他实施例中，单个卷烤炉可以加热压延卷的整个长度，或者可以加热压延卷的所选的部分。压延卷组件72包括安装或支撑在压延卷组件72上的支撑从动件88，从而在中心支撑在压延卷76上。同样地，安装支撑从动件(未示出)从而中心支撑在压延卷78上。支撑从动件88阻止压延辊在中心区域彼此弯曲。如图5C所示，卷烤炉86包括电辐射加热元件90，其配置成符合压延卷78的曲度。卷烤炉84(图5B)配置得与卷烤炉86相类似。可替代地，或者另外，压延卷76和78中的一个或两个可以是中空的并且可以限定用于热传输流体进入和排出的流动路径，热传输流体从流体供给源提供和撤销。卷76和/或卷78可以装备有耦接到卷的旋转接头，热传输流体经过该卷从而提供热量。
图5D提供了非加热压延卷组件74的透视图，除了省略卷烤炉84和86之外，其配置得与压延卷组件72相类似。在没有卷烤炉84和卷烤炉86的情况下，可以看出，与压延卷组件72中一样，压延卷组件74包括两个支撑从动件88，中心支撑在压延卷76、78上。压延卷78是中空的并且限定了用于热传输流体通过的进入和出口，热传输流体从流体供给源提供和撤销。在所示的实施例中，卷78装备有耦接到卷的旋转接头，热传输流体通过卷流过该旋转接头从而将热量从与其接触的织网54中抽出。如果需要，可以使用旋转接头92来提供加热流体从而加热压延卷78。
图5A示出了具有四个压延卷组件72和74的处理工位20，然而，本发明并非限于此，在其他实施例中，处理工位20可以包括多于四个或少于四个压延卷组件，并且可以具有或者可以不具有冷却压延卷组件和/或加热的压延卷组件。例如，在一个实施例中，没有提供冷却的压延卷组件，在织网通过收起工位22之前通过使用风扇把冷空气吹到织网上，和/或在加热的压延卷组件72之后提供一个或多个非加热的压延卷组件可以足够冷却织网54，非加热的压延卷组件与加热的压延卷组件72相隔足以使热量从织网54扩散到周围空气中的一定距离。
如图6所示，收起工位22包括置于收起框架94上的收起卷96。收起工位22包括用于收起卷96的电动机驱动的驱动器(未示出)以在织网54中维持适当张力。用于收起卷96的电动机驱动的驱动器允许收起卷从处理工位20收集合成层板200成品。
可以根据图1所示的布局中按照期望重新布置上述设备10的各个部分，例如，改变沿处理方向移动通过设备10的材料遇到各个工位的顺序，省略对于特定处理不需要的工位，或者在展开工位12和收起工位22之间添加其他工位。另外，各个工位的部件是可移动的并且可以在各自工位内重新排列它们。例如，根据需要，可以对展开工位12增加或去除一个或多个卷支撑组件26。另外，可以在展开框架24上重新排列卷支撑组件26以提供织网54中相邻合成材料36a、36b等重叠的变化程度和/或提供各个期望宽度的织网54。同样地，处理工位20的压延卷组件72、74在压延卷框架80上可移动并且可拆卸。因此，可以改变处理工位20中压延卷组件的数量、类型、顺序和/或间距以调节合成层板200最终制品中的期望特征。对于一种制品或处理来说，单个压延卷组件72或74可能足够，对于另一种制品或处理而言，可能利用三个或四个(或更多)压延卷组件。另外，可以重新排列压延卷组件72、74以提供任何期望顺序的加热压延卷组件和冷却压延卷组件：加热，然后冷却；冷却，加热，然后冷却；加热、冷却，再次加热；加热、冷却、再次加热，随后冷却等。该设备中的这种灵活性实现了用来制造各种制品的处理中的灵活性。
设备10可以包括处理控制器(未示出)，其与设备的主要控制机构通信。以此方式，处理控制器提供了中心点，在该中心点，操作者可以控制设备运行的一个或多个方面，诸如织网54通过设备的速度、织网中的张力、施加到各个辊隙的压力、加热工位18的温度、加热的压延卷组件72所提供的热量、用于铺交叉层和/或粘合织网54的工业机器人的操作等。
在一个实施例中，设备10可以用来实现图7中100概况性示出的用于制造合成层板200的方法。方法100开始于第一步骤102，例如从安装在展开工位12的卷支撑组件26上的合成材料卷36a、36b等提供各个长度的合成材料。抽取各个长度的合成材料36a等并将其排列在延伸到粘合工位14的织网54中。在粘合步骤104中，合成材料36a等在粘合工位14处被粘合到一起从而例如使用交叉层60形成织网54。
在可选的分层步骤106中，其他长度的合成材料可以被添加到织网54。例如，其他的合成材料卷可以布置到第二展开工位16上并且其他的合成材料可以从第二展开工位16展开并且铺到第一板层合成材料36a上等并且铺到交叉层60上。在此情况下，方法100可以生成合成层板200(图6)，包括两个连续的板层(每一个都来自展开工位12和16)，在板层之间具有交叉层60。
在粘合步骤104之后，并且在步骤106中在织网54上可选地铺其他的合成材料层之后，对织网54进行加热步骤108以有助于各个长度的合成材料36a等和其上的任意交叉层60粘接到一起。为此，织网54通过加热工位18，相邻的第一板层合成材料36a等被加热从而使其中的聚合材料软化，使得各个片材可以彼此粘接。在加热步骤108之后，对织网54执行处理步骤110，各个长度的合成材料36a等形成可以被收集的合成层板200。例如，在一个处理步骤110中，织网54通过处理工位20，材料受到压力作用，并且可选地在一个或多个压延卷组件72和/或74中加热和/或冷却。压延卷组件72和/或74的热量和/或压力使得相邻的合成材料36a、36b等(以及其上的任何其他合成原料)粘接在一起。在相邻的合成材料36a、36b等包括热塑性基体原料时，压延卷组件72和/或74的热量和/或压力可以足以形成基体原料。然而，如果相邻的合成原料中的一个或者两个包括热固基体原料，则可以期望提供粘合剂或本领域技术人员已知的其他附加方式来把合成原料粘接在一起。织网54在处理步骤110的一部分中被冷却，并且在收集步骤112中，合成层板200制品在收起工位22处被收集到收起卷96上。在处理步骤110中发生的冷却使得织网54被收集，例如卷绕在卷上作为合成层板200，而合成层板的相邻绕层不会彼此粘接到一起。
在图1和图5A-图5D的实施例中，织网54沿处理方向前进通过加热的压延卷组件72并且随后通过冷却压延卷组件74。加热的压延卷组件72加热合成材料使得相邻的合成材料粘接到一起。两个压延卷组件72和74还把合成元件压缩到一起从而增强接合处理。冷却压延卷组件74随后从织网54去除热量使得合成层板200的相邻层不会在环境温度下彼此结合。以此方式，有利于合成层板200的储存和处理。例如，合成层板200可以在收起工位22处被收集到收起卷96，而不会粘接相邻绕层。
通过提供足够长度的合成材料卷36a等使得制品片材能够在合成材料200从展开工位12展开时卷绕到收起卷96上，这里描述的处理和设备可以描述为“连续”工艺。
可以在合成材料中采用各种类型的纤维。示例纤维包括E玻璃和S玻璃纤维。E玻璃纤维是一种低碱性硅硼酸盐玻璃，具有良好的电气特性和机械特性以及良好的耐化学腐蚀性。这类玻璃广泛用于增强型塑料的纤维。其高抗腐蚀性使得E玻璃适于电气合成层板。符号“E”指的是电气类。
相对于E玻璃，S玻璃是具有较高强度和较高成本的材料。S玻璃为用于航空应用的具有高拉伸强度的镁铝硅酸盐玻璃。最初，“S”代表高强度。在本发明中，E玻璃和S玻璃是优选纤维。
E玻璃纤维可以以大范围的纤维重量和热塑聚合物基体材料结合到合成物中。E玻璃可以从每平方码大约10到大约40盎司(盎司/平方码)，优选地为19-30盎司/平方码，最优选地为增强型的21.4到28.4盎司/平方码。
根据热塑性基体和纤维板的组合重量，S玻璃或E玻璃纤维板在合成材料板层中的数量可以可选地适于大约40-90wt％热塑性基体，更优选地为大约50wt％到大约85wt％热塑性基体，最优选地为板层中的热塑性基体的大约60wt％到大约80wt％。
也可以结合其他纤维板，优选地结合E玻璃和/或S玻璃，而可选地替代E玻璃和/或S玻璃。这样的其他纤维板包括ECR、A和C玻璃以及其他玻璃纤维板，石英组成的纤维、镁铝硅酸盐、非碱性铝硼硅酸盐、钠硼硅酸盐、钠硅酸盐、钠钙铝硅酸盐、硅酸铅、非碱性硼硅酸铅、非碱性硼硅酸钡、非碱性硼硅酸锌、非碱性铝硅酸铁、硼酸镉、氧化铝纤维、石棉、硼、碳化硅纤维、诸如从聚乙烯、聚乙烯醇、聚偏氯乙烯、芳族聚酰胺、聚酰胺、聚苯并咪唑、聚恶二唑、聚亚苯基、PPR、石油和煤沥青(各向同性的)、中间相沥青、纤维素和聚丙烯腈衍生的石墨和碳、陶瓷纤维、例如像钢、铝金属合金等的金属纤维。
优选的有机聚合物纤维由Kevlar作为示例提供的芳族聚酰胺纤维形成。其他优选高性能、单向纤维束一般具有大于每但尼尔7克的拉伸强度。这些成束的高性能纤维更优选地为芳族聚酰胺纤维、扩展链式超高分子量聚乙烯(UHMWPE)、聚对亚苯基苯并二恶唑(PBO)和聚(2，5-二羟基-1，4-苯撑吡啶并二咪唑)[diimidazo pyridinylene(dihydroxy)phenylene](M5)中的任何一个或者组合。使用这些具有极高拉伸强度的材料特别适于制造合成弹道装甲板和需要极高弹道特性的类似应用。
在不脱离本发明的广义方面的情况下，可以用本发明所属特定领域的技术人员已知的其他纤维类型替代。例如，诸如商标名为Twaron和Technora的那些市售的芳族聚酰胺纤维等；商标名为Toray、Fortafil和Zoltek的那些市售的玄武玻璃、碳纤维；液晶聚合物(LCP)，诸如但不限于商标名为Vectran的市售的LCP。基于以上说明，本发明意在以单独或结合形式使用有机纤维、无机纤维和金属纤维。
本发明的合成板层可以可选地包括连续、切削、无规则、混合和/或编制的纤维。在特定实施例中，除了非纵向定位纤维之外，这里所述的合成板层可以包含纵向定位纤维。
聚合基体材料可以包括热固聚合体和/或热塑聚合体。热塑性聚合体树脂材料可以是高分子量热塑聚合体，包括但不限于聚丙烯、聚乙烯、尼龙、PEI(聚醚酰亚胺)和共聚合体，更优选地为聚丙烯和聚乙烯。按重量的热塑性载荷可以根据所希望使用的制品片材的物理特性需要而明显不同。
按照热塑性基体材料和纤维的重量划分，合成材料可以包含大约60wt％到大约10wt％的热塑性基体，更优选地为大约50wt％到大约15wt％的热塑性基体，最优选地为大约热塑性基体材料的40wt％到大约20wt％的热塑性基体。
这里的术语“第一”、“第二”等不表示顺序、数量和重要程序，而仅仅用来区分彼此元件。另外，这里的术语“一种”和“一个”不表示数量的限制，而是表示至少一个所引用项的存在。
尽管参考本发明的特定实施例对本发明进行了说明，但是本领域技术人员应当理解，在阅读和理解上述公开的基础上，本公开实施例的许多变形和替代将落入本发明和所附权利要求的精神和范围内。

Claims (19)

1.一种用于制造合成层板的设备，所述设备包括：
第一展开工位，至少包括第一卷支撑组件和第二卷支撑组件，每一卷支撑组件构造成旋转支撑合成材料卷；其中所述第一展开工位构造成使得，当从第一卷支撑组件抽拉第一长度的合成材料及从第二卷支撑组件抽拉第二长度的合成材料时，合成材料的第一长度和第二长度以边对边排列的方式从所述第一展开工位出现，所述第一长度不同于所述第二长度，所述边对边排列形成织网，其中第一和第二卷支撑组件沿所述织网的宽度彼此横向间隔开；
粘合工位，位于所述第一展开工位的下游，所述粘合工位形成粘合表面，所述粘合工位适于接收所述织网，其中所述粘合工位配置成粘合所述织网；
加热工位，位于所述粘合工位的下游，所述加热工位适于接收和加热所述织网，所述加热工位包括适于接收所述织网的入口、适于允许所述织网退出所述加热工位的出口、可在打开和关闭位置之间移动的盖件、及在所述织网在所述入口和所述出口之间移动时对其进行加热的热源；以及
处理工位，包括位于所述加热工位下游的至少一个压延卷组件，所述处理工位适于接收所述织网。
2.如权利要求1所述的设备，其中所述至少一个压延卷组件包括旋转安装到支撑框架的一对辊，所述辊限定在其间的辊隙，使得在操作期间，所述织网被馈送到所述辊隙使得所述辊对所述织网施加压力。
3.如权利要求2所述的设备，其中所述辊中的至少一个被加热。
4.如权利要求2所述的设备，其中所述辊中的至少一个被冷却。
5.如权利要求3所述的设备，其中所述一对辊中的至少一个辊在缩回和接合位置之间可以相对于所述一对辊中的另一个辊移动；并且其中所述设备还包括响应于从控制器发出的命令用于使得所述一对辊中的至少一个辊在所述缩回和接合位置之间相对于所述一对辊中的另一个辊移动的装置。
6.如权利要求2所述的设备，其中所述至少一个压延卷组件包括响应于从控制器发出的命令使所述一对辊中的至少一个辊旋转的第一驱动装置。
7.如权利要求3所述的设备，还包括：
与所述至少一个辊相邻定位的至少一个卷盖件；以及
卷加热器，其耦接到所述至少一个卷盖件，用于对所述至少一个辊进行加热。
8.如权利要求7所述的设备，其中所述卷加热器包括至少一个电加热元件，其耦接到所述卷盖件并且对从控制器发出的命令做出响应，使得在所述至少一个压延卷组件的操作期间，该压延卷组件的至少一个辊被加热。
9.如权利要求4所述的设备，其中所述辊中的至少一个辊在其中具有用于从中流过的热传输流体的进入的流路径；以及
旋转接头，用于将所述热传输流体提供到所述流路径。
10.如权利要求1所述的设备，其中所述热源发出红外辐射。
11.如权利要求1所述的设备，其中所述热源包括多个电加热元件，其耦接到所述盖件并且响应于从控制器发出的命令可操作。
12.如权利要求1所述的设备，其中所述热源包括引导到所述织网上的加热空气。
13.如权利要求1所述的设备，还包括：
位于所述粘合工位和所述加热工位之间第二展开工位，所述第二展开工位包括至少一个卷支撑组件，用于旋转支撑合成材料卷。
14.如权利要求1所述的设备，包括多个压延卷组件，每一个压延卷组件均包括可旋转安装到支撑框架上的一对辊，所述一对辊的每一个都在它们之间限定辊隙，使得在操作期间所述织网被馈送到所述辊隙，使得所述辊对所述织网施加压力。
15.如权利要求14所述的设备，包括至少一个受热的压延卷组件。
16.如权利要求15所述的设备，包括至少一个冷却压延卷组件。
17.如权利要求1所述的设备，其中所述第一展开工位包括展开框架，并且其中多个支撑卷组件安装在所述展开框架上；并且其中所述支撑卷组件彼此相对定位，使得在操作期间，合成材料卷从所述支撑卷组件展开，使得来自所述合成材料卷的合成材料边对边地定位从而形成加宽的合成材料片材。
18.一种用于制造合成层板的方法，包括：
提供至少包括第一卷支撑组件和第二卷支撑组件的第一展开工位；
以彼此相邻的关系定位第一卷支撑组件和第二卷支撑组件，使得当从第一卷支撑组件抽拉第一长度的合成材料及从第二卷支撑组件抽拉第二长度的合成材料时，合成材料的第一长度和第二长度以边对边排列的方式从所述第一展开工位出现，所述第一长度不同于所述第二长度，所述边对边排列形成织网，其中第一和第二卷支撑组件沿所述织网的宽度彼此横向间隔开；
在粘合工位中粘合所述织网，所述粘合工位形成粘合表面，其中所述粘合工位位于所述第一展开工位的下游；
在位于所述粘合工位下游的加热工位中加热所述织网，所述加热工位适于接收和加热所述织网，所述加热工位包括适于接收所述织网的入口、适于允许所述织网退出所述加热工位的出口、可在打开和关闭位置之间移动的盖件、及在所述织网在所述入口和所述出口之间移动时对其进行加热的热源；及
将经过加热的织网传输通过压延卷组件从而生成合成层板。
19.如权利要求18所述的方法，其中粘合所述织网包括横跨所述织网铺设交叉层。
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US8763668B2 (en) 2014-07-01
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JP2011515255A (ja) 2011-05-19
US20090266468A1 (en) 2009-10-29
EP2268469A1 (en) 2011-01-05
US9333732B2 (en) 2016-05-10
US20140311671A1 (en) 2014-10-23
CA2719229C (en) 2013-08-20
US20160243802A1 (en) 2016-08-25
CA2719229A1 (en) 2009-10-01
EP2268469B1 (en) 2016-02-17
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