CN104169077A - 平面复合材料 - Google Patents

平面复合材料 Download PDF

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Publication number
CN104169077A
CN104169077A CN201380014808.9A CN201380014808A CN104169077A CN 104169077 A CN104169077 A CN 104169077A CN 201380014808 A CN201380014808 A CN 201380014808A CN 104169077 A CN104169077 A CN 104169077A
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CN
China
Prior art keywords
composite
fibre
layer
fiber
thermoplastic
Prior art date
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Granted
Application number
CN201380014808.9A
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English (en)
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CN104169077B (zh
Inventor
B.巴瑟
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Quadrant Plastic Composites AG
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Quadrant Plastic Composites AG
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Publication of CN104169077A publication Critical patent/CN104169077A/zh
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Expired - Fee Related legal-status Critical Current
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Classifications

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    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
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    • B29C39/14—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of indefinite length
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    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
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    • Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
    • Y10T428/24074—Strand or strand-portions
    • Y10T428/24091—Strand or strand-portions with additional layer[s]
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24132—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in different layers or components parallel

Abstract

本发明涉及一种平面复合材料，包括：至少一层由热塑性纤维无纺布或热塑性薄膜构成的层A和至少两个单向的纤维预浸料层B和B'，其中，层B和B’具有双向的纤维取向。所述层不仅相互缝合而且相互针刺结合。

Description

平面复合材料
技术领域
本发明涉及一种根据权利要求1前序部分所述的平面复合材料以及用于制造这种平面复合材料的方法和一种所述平面复合材料的应用。
背景技术
热塑性塑料由于它较低的重量越来越多地被用于制造模制件、尤其用于制造机动车的构件。为了使其具有足够的强度和刚性，通常将它与强化纤维相结合。例如通过将连续玻璃纤维网与无序取向纤维(Wirrfasern)和热塑性熔条引导到一起并且在双带压力机上固化而制造由玻璃网加强的热塑性塑料制成的平面半成品。由这样得到的平面半成品能够通过热压装置被在型模内制成构件。然而，该纤维强化是不定向的，即，它等同地作用在所有方向上，没有优选方向，使得这种复合材料的强度是有限的。然而，在许多情况下需要构件在优选方向上被加强。这可以这样实现，即使用由平行的纤维束(粗纱)制成的纤维织物或纤维预浸料(Fasergelege)作为加强纤维。例如，在WO2006/111037中，描述了一种平面复合材料，该材料包含由热塑性纤维制成的无纺纤维层和由平行加强纤维束制成的织物层或者纤维预浸料层。各层可以或者针刺结合、缝合或相互热结合。这种复合材料能够通过热压装置处理为具有有针对性的加强的构件。
在针刺时，纤维束被打开，并且纤维被部分断裂。但是，在这过程中，各单个纤维略微相对移动，使得取向被部分抵消，并且降低了加强作用。在缝合时，各单个纤维束通过粘合线相互结合，并且与无纺层的纤维相结合。但是，在这过程中，纤维束未被打开，从而热塑性熔体能够仅仅不完全地浸泡织物层或纤维预浸料层，因而导致由此制成的构件的承载能力降低。
因此，本发明所要解决的技术问题是，提供一种使用纤维预浸料层加强的复合材料，该复合材料没有上述提及的缺点。本发明另一个要解决的技术问题是，提供一种平面复合材料，它在多个方向上被加强，能够利用这种平面复合材料制造具有双向被强化的构件。
原则上，如果为了强化而使用纤维织物，上述另一个技术问题也可根据WO2006/111307的复合材料所解决。不过，在编织时，纤维束在交叉点上波动，因而导致在纤维方向上的耐压强度降低。此外，在纤维束之间的交叉点处没有热塑性塑料。这些干燥位置导致不均匀的浸渍。这些缺点同样要通过本发明避免。
其它类型的平面复合材料在EP 0203803A1和US3，761，345A中有所描述。
EP 0203803A1涉及一种强化的树脂体，它含有由平行的加强纤维构成的层和由芳香尼龙纤维制成的缓冲层。该纤维组织被嵌入到硬化树脂内。芳香尼龙纤维是由芳族聚酰胺制成的高性能强化纤维，它与脂族聚酰胺相比不能融化，并且因此不能进行热塑性加工。
US 3,761,345A描述了一种纤维结构，它能够吸收树脂。此外，能够通过树脂的硬化制造玻璃纤维加强的树脂产品。该纤维结构由多个层组成。其中，纤维能够或者是单向的或者是以回路的形式存在；此外，中心层还能够由较短的中断纤维的无序取向束组成。但是，在US 3,761,345A中没有公开层内纤维至少部分地由热塑性塑料组成的无纺纤维层，此外，也没有描述通过对复合材料的热塑性热压进行的构件或半成品的制造。
发明内容
因此，本发明的一个主题是平面复合材料，包括：
-至少一层由无纺纤维构成的层A，它由重量百分比40-100％的热塑性纤维和重量百分比60-0％的强化纤维、或者热塑性薄膜组成，和
-由平行的强化纤维束构成的至少两个单向的纤维预浸料层B和B'，其中，所述层B和B′具有双向的纤维取向。
根据本发明，在复合材料中，各层不仅相互缝合而且针刺结合。
术语“热塑性塑料”在本技术领域中通常被这样理解，即，有关材料在常规加工条件下是可熔融的并且可热塑变形。
根据有利的实施例，层A的无纺纤维含有重量百分比高达50％的强化纤维。根据另一有利实施例，层A的无纺纤维不含强化纤维，并且因此只由热塑性纤维构成。根据另一个有利的实施例，层A由热塑性薄膜构成。
“双向“表示两个纤维预浸料层B和B'的关系，即纤维预浸料层B的纵轴线与纤维预浸料层B’的纵轴线不平行。
本发明的另一个主题的是制造这种复合材料的方法。在此，有两种变型方案：
在第一变型方案中，首先根据梳理法、气流成网法或者无纺纺丝法或者根据所谓的造纸方法来制造无纺纤维层A，随后双向地相互取向的纤维预浸料层B和B′与层A连续地导引到一起。之后，将层相互缝合，最后针刺结合。
在第二种变型方案中，层A的热塑性薄膜与层B和B′的双向地相互取向的纤维预浸料层彼此连续地导引到一起、相互缝合，之后针刺结合。
优选的层排列是B-A-B'和B-A-B'-A-B。其它的具有多达20层的布置也是可能的。优选的是总是将无纺纤维或热塑性薄膜层A安置在两个纤维预浸料层B或B'之间。还能够实现层A设置在外面的布置用于特殊的应用情况。
层B或B'的纤维取向是双向的，优选相对于在所述层结构中的参考方向，例如它们的纵轴线L成0°/90°、30°/-30°、45°/-45°或60°/-60°的取向。相应地，在相应纤维方向之间的锐角优选地是60°或90°。因此，层优选被对称地布置。
附图说明
图1示出层结构B-A-B'的立体图，它具有相对于纵轴线成45°/-45°的层B或B'的双向纤维取向。
各个层的面重量优选在20至1000g/m2之间，尤其在30至1000g/m2之间，更特别在150至300g/m2之间。各个定向层还能够具有不同的面重量。这样选择所述面重量，即全部强化纤维在复合材料中所占份额优选为重量百分比20-80％，尤其重量百分比30-70％并且特别优选重量百分比约60％。
优选的强化纤维是玻璃纤维和碳纤维，还能是芳族尼龙纤维、玄武岩纤维、天然纤维和由较高熔点聚合物得到的纤维，以及例如由玻璃纤维和聚丙烯纤维构成的混合纤维。优选地，纤维类型在各单独层中是相同的。纤维预浸料层的强化纤维具有优选含有在300至4800tex的纤度的纤维束。
优选的是，在无纺纤维或热塑性薄膜中的热塑性塑料是聚丙烯以及可熔融的聚酰胺，即脂族聚酰胺；另外，其它热塑性材料，例如聚酯、聚醚磺、聚醚酮和聚醚酰亚胺也是合适的。聚醚酮的特点在于良好的耐热性。如果所述热塑性塑料具有在10至400之间的熔融指数(melt flow index,MFI)(230°C，2.16kg)，尤其是在大约120克/10分钟的情况下，则能得到具有特别好的流动性的复合材料。用于制造层A的无纺纤维的热塑性塑料能够按照许多不同尺寸和几何形状来提供。
所述复合材料的各个层不仅彼此缝合而且针刺结合。
在缝合时，纤维预浸料层的纤维束通过构成网格的缝纫线相互连接。因此，强化纤维是固定在它们的平行取向内。适合的缝纫线可以由玻璃、聚丙烯、聚酰胺、PET或聚醚酮构成。还能够使用醋酸纤维线和粘合线。
优选地，缝合线由与层A的热塑性纤维或热塑性薄膜相同的热塑性塑料构成，优选也由聚丙烯或聚酰胺构成。
图2示出在缝合后沿着层B的纤维取向的图1所示层结构B-A-B’的横截面。在此，缝合线N连接层B'和B的纤维束。随后，该层结构仍被针刺结合。
通过针刺，如前面所述，能打开纤维束，而且局部破坏纤维。此外，通过织针的倒钩、热塑性纤维从无纺材料被拉入纤维束内。在针刺热塑性薄膜时也类似地发生，这时通过倒钩将片段或纱线从薄膜中拉出，并且拉进纤维束中。可用刺针在常规针刺织机(Nadelstühlen)上进行针刺。针脚的数量能够在5至100个/cm2，尤其在20和40个/cm2。
所有这样设计的结果是，由无纺纤维或热塑性薄膜构成的热塑性熔融体在随后的热压过程中能够浸入定向层和将其均匀地浸渍。如果缝合线由相同的热塑性材料构成，其在热压过程中也会熔融；在此之后，缝合线不再需要熔融。
由于纤维束被附加地相互缝合，所以它们在针刺结合时保持它们的取向，并且因为纤维预浸料层也通过缝合与纤维无纺层或与热塑性薄膜相连接，所以也就不存在所述层在传输和以后的再加工过程中出现滑移的风险，。
根据本发明的平面复合材料在热塑性塑料的软化范围以上的温度情况下能够在模具中直接地被压制成三维构件，或者所述平面复合材料能够通过热压、例如在双带压力机中被固化为优选具有厚度为0.5至5mm的平面半成品。

Claims (15)

1.一种平面复合材料，包括：
-至少一个由无纺纤维构成的层A，该层由重量百分比40-100％的热塑性纤维和重量百分比60-0％的强化纤维、或者由热塑性薄膜组成，和
-由平行的强化纤维束构成的至少两层单向的纤维预浸料层B和B'，其中，层B和B’具有双向的纤维取向，
其特征在于，所述层不仅相互缝合而且相互针刺结合。
2.根据权利要求1所述的复合材料，其特征在于，所述层结构是B-A-B’或者B-A-B’-A-B。
3.根据权利要求1或2所述的复合材料，其特征在于，所述层B和B'的纤维取向关于复合材料的参考方向成0°/90°、30°/-30°、45°/-45°或60°/-60°。
4.根据权利要求1至3之一所述的复合材料，其特征在于，各个层的面重量分别在20至1000g/m2之间，尤其在30至1000g/m2之间，更特别在150至300g/m2之间
5.根据权利要求1至4之一所述的复合材料，其特征在于，全部强化纤维在复合材料中所占份额为重量百分比20-80％。
6.根据权利要求1至5之一所述的复合材料，其特征在于，强化纤维是玻璃纤维或者碳纤维。
7.根据权利要求1至6之一所述的复合材料，其特征在于，所述层A的热塑性纤维或热塑性薄膜由聚丙烯构成。
8.根据权利要求7所述的复合材料，其特征在于，缝纫线由聚丙烯构成。
9.根据权利要求1至6之一所述的复合材料，其特征在于，所述层A的热塑性纤维或热塑性薄膜由聚酰胺构成。
10.根据权利要求9所述的复合材料，其特征在于，缝纫线由聚酰胺构成。
11.根据权利要求1至6之一所述的复合材料，其特征在于，所述层A的热塑性纤维或热塑性薄膜由聚醚酮构成。
12.根据权利要求11所述的复合材料，其特征在于，缝纫线由聚醚酮构成。
13.一种用于制造根据权利要求1所述的复合材料的方法，其特征在于，
或者：
-首先按照梳理法、气流成网法或者无纺纺丝制造无纺纤维层A，并且随后连续地将纤维预浸料层B和B’与一层或多层无纺纤维层A导引到一起，然后将这些层相互缝合，并且随后针刺结合；
或者：
-将层A的热塑性薄膜与纤维预浸料层B和B’连续地导引到一起，然后将所述层相互缝合，并且随后针刺结合。
14.一种根据权利要求1至12之一所述的复合材料的应用，用于通过在模具内的热压制造三维构件。
15.一种根据权利要求1至12之一所述的复合材料的应用，用于通过在双带压力机内的热压制造厚度为0.5至5mm的平面半成品。
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US20180001594A1 (en) 2018-01-04
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US20150030804A1 (en) 2015-01-29
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