CN102227304A - 用于通过直接法制造复合材料部件的具有恒定宽度的新型中间材料 - Google Patents

用于通过直接法制造复合材料部件的具有恒定宽度的新型中间材料 Download PDF

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Publication number
CN102227304A
CN102227304A CN2009801474604A CN200980147460A CN102227304A CN 102227304 A CN102227304 A CN 102227304A CN 2009801474604 A CN2009801474604 A CN 2009801474604A CN 200980147460 A CN200980147460 A CN 200980147460A CN 102227304 A CN102227304 A CN 102227304A
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band
tow
width
monofilament
described band
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Inventor
让-马克.贝劳德
阿兰.布鲁耶尔
让-弗洛伦特.拉梅瑟
雅克.杜卡尔
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Hexcel Fabrics SA
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Hexcel Fabrics SA
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Abstract

本发明涉及制备在其每个表面上与聚合物粘合剂(2a，2b)相结合的加固丝束(l)或单丝的条带(I)的方法，所述条带沿其整个长度(l)具有基本恒定的给定宽度(L)，其中所述丝束或单丝沿平行于条带长度的方向伸展，特征在于所述方法包括以下步骤：a)使用校准装置(13)将条带宽度调节至希望的宽度，b)使条带在其每个表面上与粘合剂结合，以确保条带的均匀粘着，使得粘合剂总重量不超过所得条带总重量的25％。本发明还涉及可通过该方法获得的条带。

Description

用于通过直接法制造复合材料部件的具有恒定宽度的新型中间材料
技术领域
本发明涉及适于形成复合材料部件的加固材料的技术领域。更具体地，本发明涉及新型中间材料(其用于通过随后注射或灌注热固性树脂制造复合材料部件)、从该材料的堆叠物(stack)中制造复合材料部件的方法，以及获得的复合材料部件。
背景技术
复合材料部件或物品(即，一方面，含有一个或几个加固物或纤维层，另一方面，含有可包含热塑性材料的主要热固性基质(″树脂″)的部件或物品)的制造可例如通过称为″直接法″或″LCM″(来自英语″液体复合材料成型(Liquid Composite Moulding)″)的方法实现。直接法通过以下事实定义：一个或多个纤维加固物以″干″状态制备(即，不含最终基质)，树脂或基质单独制备，例如通过注射到含有纤维加固物的模具中(″RTM″法，来自英语″树脂传递成型(Resin Transfer Moulding)″)，通过遍及纤维加固物的厚度灌注(″LRI″法，来自英语″液体树脂灌注(Liquid Resin Infusion)″或″RFI″，来自英语″树脂膜灌注(Resin Film Infusion)″)，或者可选择地，通过用辊或刷在纤维加固物的每一单元层上手工涂覆/浸渍并连续施用在模具上。
称为直接法的其它方法使用预浸渍材料，其已经含有足够比例的树脂用于形成希望的复合材料部件。该材料清楚地描述在文献US 2005/048280、WO 92/20521和EP 0 554 950中。
对于RTM、LRI或RFI法，通常首先必须的是制造希望的最终产品的模型的纤维预成型件(preform)，然后用树脂浸渍该预成型件。通过不同压力，在适当温度注射或灌注树脂，然后一旦在预成型件中含有全部必需的树脂量，使组合达到较高温度以完成聚合/成网周期，并因此固化。
在机动车、航空或航海工业中使用的复合材料部件特别容易受到非常严格的要求，尤其是在它们的机械性质方面。因此，特别重要的是使用一方面非常稳定，另一方面易于处理和加工的材料。
在这些领域中，大量预成型件从加固材料(主要是碳纤维，特别是单向碳纤维)形成。为了满足所需要的高的质量标准和生产力(特别是航空领域)，日益需要实现自动化方法。因此需要具有规则结构和特别小的宽度偏差的单向材料，以尽可能避免在覆盖(draping)或自动放置(deposition)中两个相邻加固物间的材料空隙((gap)或重叠(overlap)。
现有技术提供了加固丝束(strands)的单向层，其中丝束间的内聚通过相对于所述加固丝束横向拉伸的热塑性粘合丝束或玻璃/热塑性织造或非织造织物来保证。该层例如由SIGMATEX UK Limited，Runcom Cheshire WA7 1TE，United Kingdom以PW-BUD销售。
在这些条带上，丝束间的粘合仅限于点粘合，加固纤维在粘合丝束之间是自由的。结果，存在大的宽度偏差(特别是在粘合丝束之间)，从而产生0.40-1.00mm的宽度标准偏差。
而且，当平行于加固丝束的方向(通常称为0°轴)切割该单向层以获得希望的宽度时，切割边缘不平整以及留有单丝片段。这些切割纤维对于随后的过程通常是非常不方便的，例如在线圈(称为″环″)上形成软块(wads)、材料缠绕(material windings)。
因此，本发明目的在于提供实现具有高度一致的给定宽度的单向层的方法，其适于从一个或多个丝束制造复合材料部件的直接法，同时限制材料损失。
本发明的另一个目的是提供制造沿主要方向无切割纤维的单向层的方法。
在这方面，本发明目的在于提供制备在每一面上与聚合物粘合剂相结合的加固丝束或单丝的条带的方法，所述条带具有遍及整个长度基本恒定的给定宽度，其中所述丝束或单丝在平行于条带长度的方向上伸展，其特征在于包括以下步骤：
a)借助于定尺寸设备将条带宽度调节至希望的宽度，
b)在每一面上使条带与聚合物粘合剂相结合，以确保条带的均匀内聚，使得粘合剂的总重量小于所得条带总重量的15％。
所述聚合物粘合剂例如为一种或多种热塑性和/或热固性聚合物的粉末或一种或多种热塑性和/或热固性聚合物的非织造织物。在条带的两面上使用非织造布是特别优选的。
当聚合物粘合剂为作为聚合物粘合剂的热固性或优选热塑性纤维的非织造布或织物时，有利的是在调节条带宽度后使其与条带结合，以维持调节后得到的宽度。因此，可将条带依尺寸制成希望的宽度(该宽度遍及它的整个长度基本恒定)，并通过使纤维条带与聚合物粘合剂粘合结合固定得到的尺寸，从而将宽度偏差最小化。
根据一种实施方案，使纤维条带在其每一面上与宽度大于条带宽度的非织造布或织物相结合，并在条带的每一条边缘热切割非织造布或织物。特别是，该过程使得可以在没有碎屑的情况下得到清晰的(sharp)边缘，这是由于所述切割不在丝束上进行，而是沿着丝束边缘且在丝束外面进行。另外，在切割期间加热非织造布，直到聚合物粘合剂至少部分地熔融。一旦冷却，所述聚合物则可以维持条带尺寸。理想地，特别是当所述非织造布或织物在条带边缘之外的超出部分(overflow)足以切割时，并且当所述切割不距离条带边缘太近进行时，将位于条带每一面上的两份粘合剂粘合起来，以将丝束或单丝的条带基本上包封在粘合剂封套内。
作为此最后方案的一部分，为了进一步促进实现清晰边缘和条带宽度的良好控制，一方面将条带()和另一方面将从条带每一边缘切割的部分()通过诸如进料辊或抽吸的手段除去。
本发明方法使得可以从单一加固丝束或从数个加固丝束制造给定宽度的材料，所述加固丝束沿着平行于材料长度的方向伸展。
在本发明的上下文中，得到具有基本恒定宽度的条带，即，在整个长度上宽度偏差非常小的条带。将长度视为表示最小约一百米。将条带或带子视为表示长度远大于宽度的材料层。通常，根据本发明方法制备的条带具有非常长的长度，特别是能够匹配市场上可利用的丝束的长度。借助于本发明方法，在整个长度上条带宽度的标准偏差明显小于0.25mm，优选0.22mm，且优选小于或等于0.20mm。条带宽度和标准偏差可根据表3实施例中所述的方法测定。可将标准偏差定义为平均值偏差的均方根，如在下式中：
1 n Σ i ( x i - x ‾ ) 2
其中：
n＝数值的数目
xi＝一个数值
由于它们基本恒定的宽度，本发明条带还呈现出非常小的表面密度偏差。
本发明方法可用于制造这样的条带：每个条带由单一丝束(相当于单丝集合)制成，以及可用于制造这样的条带：每个条带由数个丝束制成。
同样可实施本发明方法以同时制造数个条带。
此外，本发明目的在于在每一面上与聚合物粘合剂相结合的加固丝束或单丝的条带，其中所述丝束或单丝在平行于条带长度的方向上伸展，特征在于所述条带的给定宽度在整个长度上基本恒定，以及标准偏差明显小于0.25mm，优选小于0.22mm并且优选小于或等于0.20mm。
此外，本发明目的在于可根据上文和下文所定义的方法的不同方案得到的条带。
参见附图，各种其它特征从下面的描述显现。
图1和2分别为在本发明上下文中得到的条带的透视剖面图和横截面图，用于与两份非织造材料相结合的单向层的情况。
图3为在本发明上下文中得到的条带的俯视图，用于在每一面上与粉末相结合的单向层的情况。
图4为在本发明上下文中得到的条带的照片，用于说明它的非常清晰的边缘。
图5示意性地描绘出制造在每一大面上与非织造材料相结合的条带的设备的一览图。
图6示意性地描绘出移动通过铺展和定尺寸设备的丝束或丝束组合。
图7描绘出图3的项D(item D)，其对应于与聚合物粘合剂相结合之前的定尺寸元件，用于同时制造数个基于单一丝束的条带的情况。
图8描绘出切割设备的局部视图，用于并行制造数个条带的情况。
图9A、9B和10比较了用一方面的根据本发明使193g/m2的单向层(用IMA GS 12K和446tex的28根丝束获得，宽度为64.7mm)与两份非织造布相结合的条带，和另一方面的用相同丝束(但是未定尺寸)和相同的两份非织造布制造的条带获得的平均宽度和标准偏差。
图11、12A和12B比较一方面根据本发明使126g/m2的单向层(用1个785 tex AS7JK 12K的丝束获得，平均宽度为6.21mm)与两份非织造布相结合的条带，和另一方面用相同丝束(但是未定尺寸)和相同的两份非织造布获得的条带。
图13显示出根据本发明使304g/m2的单向层(用1个785 tex AS7JK 12K的丝束获得，平均宽度为2.58mm)与粉末相结合的条带的宽度分布。
本发明方法使得可以定尺寸和控制单向纤维条带的宽度，以及通过使单向加固纤维与确保均匀粘合的聚合物粘合剂相结合来固定条带尺寸。特别地，该条带可提供3-600mm的宽度，因此可从一个或数个丝束获得(丝束由单丝集合组成)。当使用一个或多个非常细的1K或3K丝束时，甚至可获得较窄条带。
如图1中所示，在本发明上下文中制造的条带I具有长度l和宽度L。这些条带由单丝集合(单一丝束1的情况)组成或由丝束1的组合(每个丝束1由单丝集合组成)组成，其平行于条带宽度伸展。条带具有通常矩形的形状和在其每个大面1a和1b上与聚合物粘合剂相结合，如图2中所示。图1和2图示了聚合物粘合剂为两份非织造布2a和2b的情况，以及图3图示了聚合物粘合剂为遍及条带I的两个面分布的粉末3的情况。
将加固单丝或纤维定位，以确保遍及条带的整个表面准-完全覆盖。具体地，当条带由数个丝束的单向层组成时，将丝束边靠边地排列。当在形成条带之前将单向层的总宽度调节成恒定，使其具有最小的宽度标准偏差时，通过在材料中将任何空隙(英语中的″gap″)或重叠(英语中的″overlap″)最小化并且甚至避免来调节层宽。
丝束通常由丝束或单丝的集合组成，以及通常在碳丝束的情况中含有1,000-80,000根单丝，并且有利的是含有12,000-24,000根单丝。在本发明上下文中使用的加固丝束优选为选自以下的材料：碳、陶瓷、玻璃、二氧化硅、玄武岩或芳族聚酰胺，或者在复合材料领域中使用的任何其它材料，其中纤维为天然或合成的。不过，碳是特别优选的。明显地，可使用的陶瓷为碳化硅和耐高温氧化物，例如氧化铝和氧化锆。在本发明上下文中特别优选使用的为1-24K碳丝束，并且优选为12和24K碳丝束。组成纤维优选为连续的。常用丝束具有基本圆形的横截面(称为圆形丝束)，或者优选地，为基本上平行立六面体的(parallelepipedic)或椭圆形的(称为扁平丝束)。这些丝束具有一定的宽度和厚度。作为实例，扁平3K和200tex碳丝束通常具有1-3mm的宽度，扁平12K和446tex碳丝束具有2-5mm的宽度，12K和800tex扁平丝束具有3-7mm的宽度，24K和1600tex扁平碳丝束具有5-12mm的宽度，以及24K和1040tex扁平碳丝束具有5-10mm的宽度。因此，具有3,000-24,000根单丝的扁平碳丝束将在多数情况下具有1-12mm的宽度。在所述碳丝束中值得注意的是拉伸模量为220-241Gpa以及应力破裂为3450-4830MPa的高阻(HR)丝束，拉伸模量为290-297Gpa以及拉伸应力破裂为3450-6200MPa的中模量丝束(IM)，和拉伸模量为345-448Gpa以及拉伸应力破裂为3450-5520Pa的高模量丝束(HM)(来自″ASMHandbook″，ISBN 0-87170-703-9，ASM International 2001)。
条带由一个或数个丝束制造。在条带由数个丝束组成的情况中，将丝束组合(并非每个单独的丝束)定尺寸，以制造具有给定宽度的层。可将一个丝束或多个丝束从绕轴牵伸以及可在定尺寸阶段之前铺展。为此目的，可使一个丝束或多个丝束进入例如包括一个或数个铺展棒12的铺展设备，如图6中所示。该铺展步骤可为必需的，取决于希望的每单位面积重量以及为了在定尺寸之前获得大于在定尺寸之后希望的宽度的层宽或丝束宽度。这种定尺寸系统可通过棒12补充，所述棒12沿着它的长度振动，位于棒10和11的出口处，刚好在定尺寸设备13的前面，如图6中所示。类似地，当将高计数丝束的结合体用于非常低的表面密度时，该设备可通过数个类似于棒12的振动棒补充。
所述定尺寸阶段通过以下方法实施：使所述层或丝束通过定尺寸设备，其可为具有给定宽度的开口，特别为在辊上切割的平底凹槽的形式，或在基于一个或数个丝束的单一条带情况中的在两个齿之间的开口，或在并行制造数个条带情况中的用于数个丝束的限定定尺寸开口的定尺寸梳，如图7中所示。当形成包括数个丝束的层时，实际上和严格说来，层宽的定尺寸仅在两个外部丝束上进行，其它丝束由位于铺展单元前面的梳(comb)引导，使得在层中的丝束之间不存在自由空隙。
在定尺寸设备的出口处，定尺寸的单向层将在它的整个长度上具有准-恒定宽度，该宽度将在整个过程中保留，直到获得最终的条带。优选地，在定尺寸设备的出口处，定尺寸的单向层的宽度在单向层的整个长度上的标准偏差将明显小于0.25mm，优选低于0.24mm，并且优选小于或等于0.20mm。在单向纤维的条带在每个面上与粉末相结合的情况中，定尺寸可在与粉末结合之前和/或之后进行。在聚合物粘合剂为织物或非织造布的情况中，定尺寸将在其与单向条带结合之前进行。
此外，在聚合物粘合剂为织物或非织造布(特别地，热塑性材料)的情况中，将在定尺寸设备的出口处得到的定尺寸的单向层在每个面上与热塑性织物或非织造布结合，例如在通过辊驱动的传送带上。在定尺寸设备出口和使所述层与聚合物粘合剂相结合的设备(在说明的实例中的传送带)之间的距离优选非常小，约为几毫米，以保持所得的定尺寸。为了使它们能够在冷却后与丝束或单丝粘合，使非织造布在与条带结合之前经历加热阶段，从而导致聚合物软化，并且甚至熔融。选择非织造布的宽度，使得它将伸展到单向层的两侧之外。加热和压力条件适合包括非织造布的材料和它们的厚度。在多数情况下，热压阶段将在Tf nonwoven-15℃至Tf nonwoven+60℃(Tf nonwoven表示非织造材料的熔融温度)的温度和在0.1-0.6MPa的压力实施。因此非织造布可在结合之前和之后达到1-10的压缩比率。非织造材料在碳单向材料上的层压阶段对于正确控制中间产品的最终厚度同样是重要的。实际上，取决于温度和压力条件，特别是在层压期间，可改变并因此调节在中间产品的每一侧上的非织造布厚度。
非织造布在与单向层结合之前的厚度将取决于它们与单向纤维层结合的方式进行选择。在多数情况下，它们的厚度将非常接近于希望的条带厚度。也可在结合阶段中选择使用较厚的在一定温度层压的非织造布，以达到希望的厚度。在优选的方式中，使单向纤维层在其每个大面上与两份基本相同的非织造布结合，以得到完全对称的中间产品。在与单向层结合之前非织造布的厚度为0.5-200μm，并且优选为10-170μm。在本发明中间产品上，每一非织造布的厚度为0.5-50微米，并且优选为3-35微米。在结合之前不同非织造布的厚度通过标准NF EN ISO 9073-2，使用方法A，用2827mm2的测试面积(60mm直径圆盘)和0.5kPa的外加压力测定。
然后将条带借助于进料辊(三个牵引辊)从传送带引出并使用热切割设备且特别为加热的刀沿其每个纵向边缘进行切割。切割不在丝束中进行，而是紧邻丝束边缘进行，以避免任何破损。在条带的每个边热切割非织造布，在条带中导致一定的收缩。因为两份非织造布比单向层宽度宽，它们显示出与彼此的点状粘合(spot adhesion)，优选在碳边缘处限制(trap)单向层。因此所得条带具有非常清晰的边缘4，没有切割单丝的片段，如图4中所示。
然后将条带通过三个牵引辊引出。通过借助于进料辊或借助于抽吸除去非织造布碎屑，同样可以(甚至更加)促进非常清晰的边缘的形成。
图5显示能够制造本发明条带的设备的简化图解，所述条带使用丝束(特别是碳)单向层，该单向层在其每个大面上与非织造布(特别是热塑性材料)相结合。
使一个碳丝束或多个碳丝束1从安装在集束架(creel)101上的碳绕轴(spool)100退卷，通过梳102，并通过导辊103导入机器的轴。然后将碳丝束用加热棒11和铺展棒12铺展，然后用定尺寸设备定尺寸，以得到具有希望的宽度的单向层。将非织造布104a和104b的卷无张力退卷并通过安装在自由旋转辊106a、106b、106c、106d和加热棒107a、107b之间的传送带105a和105b传送。将非织造布2a和2b在与碳丝束1接触之前在区域108a和108b中预热并层压在控制了空气空隙的两个加热棒107a和107b的每侧上。然后可冷却压延机108在每侧上具有非织造布的单向层上施加压力，接着将所述层导向切割设备109。回转辊110可以将条带I再次导向由三个牵引辊111组成的牵引系统，接着导向卷绕辊112，以形成由条带I组成的卷。
同样可同时制造数个条带，在这种情况中将组成条带的每个丝束或丝束组合铺展(如果需要的话)并单独定尺寸，以及将不同的条带彼此间隔放置，在每个丝束之间留有足够空间，以使得能够切割。然后将覆盖丝束和间隔的单一非织造布与所有条带在它们的每个面上结合，如图8中所示。然后切割可优选在每个条带之间实施，而不会在切口之间产生非织造布的碎屑，使用如图8中所示的设备，和平行的、间隔开的以及偏移量为条带宽度的数排(在图示的实例中为两排)切割设备120。
为了进一步促进清晰边缘的形成和条带宽度的良好控制，将在边缘两侧上切掉的部分借助于进料辊或通过抽吸除去。在这种情况中，与碎屑相对应的末端含有非织造布仅可在一侧上切割的丝束，其将促进通过进料辊或通过抽吸除去碎屑。也可在预期进行切割和担任碎屑角色的边缘上放置与用于形成条带的丝束具有不同性质的丝束。这适用于形成单一条带，以及适用于并行制造数个条带的情况。
以此方式制造的一个条带或多个条带的宽度可在贮存之前通过光学测量系统控制。根据该连续过程，单向纤维条带能以非常长的长度制造。因为它们的柔性，当离开生产线时可将条带立刻卷绕，作为卷贮存。这些绕轴可具有电影绕轴(movie spools)的方式的凸缘，或者在高级应用中，在机器的出口处直接卷绕在圆柱状绕轴上，如同供应商交付的碳丝束绕轴一样。
在条带在其每个面上覆盖有热塑性或热固性粉末的情况中，实施任何切割均是无用的。在条带与粉末结合之前和/或之后，可将条带通过上述定尺寸设备定尺寸。
根据一种优选的实施方法，将优选加热的定尺寸的条带在其每个面上与粉末结合，特别是通过将外壳静电上粉。然后通过以下方法有利地实现冷却：维持先前获得的定尺寸，并再次将带有粉末的条带转移至如前所述的定尺寸设备。该设备(例如图7中所示的圆梳)取决于所得条带的数目具有一个或数个通道，使条带可在粉末施用和冷却期间维持恒定宽度。
本发明方法涉及干燥纤维的定尺寸的丝束或单向片材的制造，即，预期用于称为″直接法″的方法。此外，聚合物粘合剂的重量少于条带总重量的15％，并且优选为条带总重量的0.1-10％，并且有利地为条带总重量的3-10％。
在本发明的上下文中，与间隔的丝束的制造不同，优选的是使用提供随机和各向同性覆盖的粉末或非织造布粘合剂，从而使得可以确保在所有方向上均匀粘着。在聚合物粘合剂和单向条带之间的粘合通过以下方法实现：加热，利用聚合物粘合剂的热粘性，接着冷却。特别优选的是使用非织造布，其在与纤维结合之前提供易于处理的性和内聚性。
例如，所述聚合物粘合剂可为选自以下的热塑性材料：聚酰胺(PA：PA6、PA12、PA11、PA6.6、PA 6.10、PA 6.12，...)、共聚酰胺(CoPA)、醚或酯嵌段聚酰胺(PEBAX、PEBA)、聚邻苯二甲酰胺(PPA)、聚酯(聚对苯二甲酸乙二醇酯-PET-、聚对苯二甲酸丁二醇酯-PBT-...)、共聚酯(CoPE)、热塑性聚氨酯(TPU)、聚缩醛(POM...)、聚烯烃(PP、HDPE、LDPE、LLDPE...)、聚醚砜(PES)、聚砜(PSU...)、聚亚苯基砜(PPSU...)、聚醚醚酮(PEEK)、聚醚酮酮(PEKK)、聚苯硫醚(PPS)、聚醚酰亚胺(PEI)、热塑性聚酰亚胺、液晶聚合物(LCP)、苯氧基聚合物(phenoxys)、嵌段共聚物如苯乙烯-丁二烯-甲基丙烯酸甲酯共聚物(SBM)、甲基丙烯酸甲酯-丙烯酸丁酯-甲基丙烯酸甲酯共聚物(methylmethacrylate-acrylate of butyl-methylmethacrylate copolymers)(MAM)和它们的混合物。
所述聚合物粘合剂也可为热固性粘合剂，例如环氧聚合物、不饱和聚酯、乙烯基酯、聚氨酯、酚醛塑料、聚酰亚胺、双马来酰亚胺或热塑性塑料/热固性塑料混合物。
在聚合物粘合剂为非织造布形式的情况中，优选使用热塑性纤维非织造布，其具有上述材料或上述不同热塑性材料的纤维的混合物。特别地，可使用的热塑性纤维非织造材料可为例如由Protechnic公司(66，rue des Fabriques，68702-CERNAY Cedex-France)或Spunfab Ltd./Keuchel Associates，Inc.(175Muffin Lane Cuyahoga Falls，OH 44223，USA)销售的非织造布。该非织造材料(也称为veils)可由长纤维或短纤维组成。具体地，构成所述非织造布的纤维将具有0.5和70μm的平均直径(在与单向层结合之前)。在短纤维非织造布的情况中，所述纤维将具有例如1-100mm的长度。
本发明单向纤维条带可用于制造要求高机械性能的航空部件，以及特别可用于制造基本部件，例如用于机身、翼板或任何其它复杂部件，例如风机叶片。该部件可通过任何已知的直接法如树脂灌注或注射来制造。
下面的实施例说明本发明，但是不限制本发明。
碳丝束AS7 J和GS 12K和IMA GS 12K由公司HEXCEL Corporation，Stamford，CT USA销售。
3g/m2共聚酰胺非织造材料1R8D03由Protechnic公司销售。
作为参照，遍及500m的长度测量非定尺寸的单向层(208个丝束用于321g/m2的表面密度，158个丝束用于250g/m2的表面密度，以及78个丝束用于125g/m2的表面密度)的宽度，每隔5m进行手动测量，该单向层每隔50米不与除了横向热熔丝束(每50mm)以外的聚合物粘合剂结合，。在下表1中示出所得结果。
表1
  AS7J 12K   平均宽度(mm)   标准偏差(mm)
  321g/m2   519   1.1
  250g/m2   506   1.8
  125g/m2   499   0.3
标准偏差看来在0.3和1.8mm之间变动。
然后实施本发明方法。使用如图5中所示的机器。加热的切割设备的目录编号为：LOEPFE BROTHER，LIMITED公司，Wetzikon，Switzerland的Thermocut TC-1。
在表2中示出操作条件。
表2
Figure BDA0000064286610000111
在表3中列出所得条带的特征。
用下列设备测量宽度的平均值和标准偏差：将条带从其支撑体以每分钟1.2m的恒定速度和200-400cN的恒定张力退卷，然后放在距离照相机(型号Baumer Optronic Type FWX 20，焦距20mm，1624x1236像素(Baumer Optronic Gmbh，Germany))265mm处，在此位置无支撑。照相机设定为：1像素等于0.05mm，其相当于1640像素x 0.05＝82mm的照片尺寸。然后每隔38mm进行照相，最小长度为50m，对应于最少1315个宽度测量值。
然后，程序NEUROCHECK 5.1(Neurocheck Gmbh，Germany)分析图像并将宽度值存放在文件中，以通过程序MINITAB(Minitab Inc，USA)统计处理。
表3
Figure BDA0000064286610000112
标准偏差看来在0.12和0.21mm之间变动以及不取决于条带宽度。
图9A、9B和10比较了本发明的193g/m2的条带(用28个446tex IMA GS12K丝束获得，宽度为64.7mm)与由相同丝束制造，但是未定尺寸和具有相同非织造布的条带的平均宽度和标准偏差。在本发明条带的情况中，所得标准偏差为0.12mm，而在未定尺寸的情况下标准偏差为0.57mm。
图11、12A和12B比较了根据本发明使126g/m2的单向片材(用1个785tex AS7JK 12K丝束形成，平均宽度为6.21mm)和两份非织造布结合的条带与用相同丝束形成，但是未定尺寸和具有相同的两份非织造布的条带。在本发明条带的情况中，所得标准偏差为0.18mm，而在未定尺寸的情况下，标准偏差为0.44mm。
还实施了本发明方法以制造在每个面上具有粉末的条带。下述机器在表4中所述的操作条件下使用。所述机器包括：
-如图6和7中所示的铺展设备10、11和12和定尺寸设备13，
-在呈圆梳形式的定尺寸设备13的出口处，将丝束的单向片材变为(bring into)静电上粉的外壳中，其中静电枪(electrostatic gun)与丝束的距离为d，与丝束形成角度a，
-在上粉的外壳的出口处，用短波红外线辐射将粉末固定在丝束上，
-然后使条带经过新的如图7中所示的圆梳，然后在空气冷却之前经过简单的棒(simple bar)。
所用粉末为含有硬化剂的环氧树脂(7P160，来自公司Akzo Nobel)。静电枪为OPTIGUN OA02型，商标为GEMA(ITW GEMA GmbH，Switzerland)。振荡器(agitator)仅在上粉期间操作，以避免粉末的融合(amalgamation)。
表4
Figure BDA0000064286610000121
Figure BDA0000064286610000131
在表5中示出所得条带的特征。
表5
Figure BDA0000064286610000132
图13示出根据本发明使304g/m2的单向片材(用1个785tex AS7JK 12K丝束形成，宽度平均值为2.58mm)和粉末相结合的条带的宽度分布。所得标准偏差为0.12mm，而在不定尺寸的情况下标准偏差为0.44mm。

Claims (16)

1.制备在每个面上与聚合物粘合剂相结合的加固丝束或单丝的条带的方法，所述条带在其整个长度上具有基本恒定的给定宽度，其中所述丝束或单丝在平行于所述条带长度的方向上伸展，特征在于所述方法包括以下阶段：
a)借助于定尺寸设备将所述条带宽度调节至希望的宽度，
b)使所述条带在其每个面上与粘合剂结合，以确保所述条带的均匀粘着，使得所述粘合剂的总重量少于所得条带总重量的15％。
2.权利要求1的方法，其特征在于所述聚合物粘合剂为一种或数种热塑性和/或热固性聚合物的粉末。
3.权利要求1的方法，其特征在于所述粘合剂为一种或数种热塑性和/或热固性聚合物的非织造布或织物。
4.权利要求3的方法，其特征在于使所述粘合剂与所述条带在调节了所述条带宽度后相结合，以维持调节后所得的宽度。
5.权利要求4的方法，其特征在于所述非织造布或织物的宽度大于所述条带宽度，以及所述非织造布或织物的热切割在所述条带的每个边缘进行。
6.权利要求5的方法，其特征在于一方面将所述条带和另一方面将从所述条带的两个边缘切割的部分通过进料辊或通过抽吸除去。
7.前述权利要求中的任一项的方法，其特征在于条带宽度在其整个长度上的标准偏差小于0.25mm，优选小于0.22mm，并且优选小于0.20mm。
8.前述权利要求中的任一项的方法，其特征在于所述条带由相当于单丝集合的单一丝束形成。
9.前述权利要求中的任一项的方法，其特征在于所述条带由数个丝束形成。
10.前述权利要求中的任一项的方法，其特征在于同时形成数个条带。
11.前述权利要求中的任一项的方法，其特征在于所述聚合物粘合剂的重量为所述条带总重量的0.1～10％，并且优选为所述条带总重量的3～10％。
12.前述权利要求中的任一项的方法，其特征在于所述丝束或单丝的材料选自下列材料：碳、玻璃、芳族聚酰胺、二氧化硅、陶瓷和它们的混合物。
13.前述权利要求中的任一项的方法，其特征在于所述聚合物粘合剂为选自以下的材料：聚酰胺(PA：PA6、PA12、PA11、PA6.6、PA6.10、PA6.12、...)、共聚酰胺(CoPA)、醚或酯嵌段聚酰胺(PEBAX、PEBA)、聚邻苯二甲酰胺(PPA)、聚酯(聚对苯二甲酸乙二醇酯-PET-、聚对苯二甲酸丁二醇酯-PBT-...)、共聚酯(CoPE)、热塑性聚氨酯(TPU)、聚缩醛(POM...)、聚烯烃(PP、HDPE、LDPE、LLDPE....)、聚醚砜(PES)、聚砜(PSU...)、聚亚苯基砜(PPSU...)、聚醚醚酮(PEEK)、聚醚酮酮(PEKK)、聚苯硫醚(PPS)、聚醚酰亚胺(PEI)、热塑性聚酰亚胺、液晶聚合物(LCP)、苯氧基聚合物、嵌段共聚物如苯乙烯-丁二烯-甲基丙烯酸甲酯共聚物(SBM)、甲基丙烯酸甲酯-丙烯酸丁酯-甲基丙烯酸甲酯共聚物(MAM)和它们的混合物。
14.在每个面上与聚合物粘合剂结合的加固丝束或单丝的条带，其中所述丝束或单丝在平行于所述条带长度的方向上伸展，其特征在于所述条带的给定宽度在其整个长度上基本上恒定以及标准偏差明显小于0.25mm，优选小于0.22mm并且优选小于或等于0.20mm。
15.权利要求14的条带，其特征在于它沿其纵向边缘没有切割的纤维。
16.权利要求14或15的条带，其可根据权利要求1-13中的任一项中限定的方法得到。
CN2009801474604A 2008-11-28 2009-11-23 用于通过直接法制造复合材料部件的具有恒定宽度的新型中间材料 Pending CN102227304A (zh)

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