CN104416911A - 包含碳纤维和天然纤维的成型制品,其制造方法及应用 - Google Patents

包含碳纤维和天然纤维的成型制品,其制造方法及应用 Download PDF

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CN104416911A
CN104416911A CN201410523990.7A CN201410523990A CN104416911A CN 104416911 A CN104416911 A CN 104416911A CN 201410523990 A CN201410523990 A CN 201410523990A CN 104416911 A CN104416911 A CN 104416911A
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fibrofelt
fibrage
scope
fiber
per unit
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马克·A·海耶斯
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Collins and Aikman Products Co
International Automotive Components Group North America Inc
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Collins and Aikman Products Co
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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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Abstract

纤维毡，包含第一纤维层，所述第一纤维层通过将45-55wt％的合成聚合物纤维、35-45wt％的天然纤维、和5-15wt％的碳纤维组合而形成，以及包含由纤维毡形成的模制基体的成型制品，所述纤维毡包含通过将45-55wt％的合成聚合物纤维、35-45wt％的天然纤维、和5-15wt％的碳纤维组合而形成的第一纤维层。

Description

包含碳纤维和天然纤维的成型制品,其制造方法及应用
技术领域
本发明涉及包含碳纤维和天然纤维的轻质成型制品的制造，以及相关的工艺和制造方法。
背景技术
具有环保意识的制造可试图通过回收/再生材料、以及源自可再生资源的材料的使用来降低其产物的碳足迹。
在运输工业中，许多制品由纤维增强复合物形成，其中纤维通常被嵌入于固化树脂中。特别地，航空工业将碳纤维增强复合制品用于许多结构部件会利用，因为这样的材料的强度-重量比高。
制造碳纤维增强复合制品的过程必然会产生工艺废料。来自碳纤维增强复合制品制造的工艺废料可能包括未使用的(新的)碳纤维，以及经多种的表面处理(例如粘结剂)和树脂浸渍的碳纤维。这样的废料通常为边角废料或者不合格的(存在缺陷的)成型制品的形式。
此外，碳纤维增强复合制品自身同样地会在其使用期限终止时变为废料。与制造废料相反，期限终止(EOL)废料可能包括嵌于已被暴露于环境中的固化树脂中的碳纤维。EOL废料可能包括在制造之后添加至碳纤维增强复合制品的其它组件(例如涂层、紧固件)以及污染物。
已研发工艺从而在多个制造阶段以及在制品的使用期限终止时由纤维增强复合制品再生碳纤维。然而，考虑到再生碳纤维的特性被认为劣于新的碳纤维，在航空业中，将这样的再生碳纤维再次掺混至航空部件中存在着阻力。
另一方面，在汽车工业中，汽车的制造并不广泛利用新的碳纤维。除了在要求碳纤维增强复合制品的强度-重量比的有限应用之外，出于经济利用的原因通常认为新的碳纤维过于昂贵。相反地，汽车制造许多年来使用玻璃纤维，并且最近才更多地使用某些天然纤维、特别地是用于重量降低。然而，天然纤维通常并不会提供玻璃纤维的物理特性或尺寸稳定性。
对于某些汽车应用需要改善的纤维增强物，其将进一步降低重量，并提供物理特性和尺寸稳定性的增强，同时没有明显不利的成本影响。
发明内容
在本发明的一种实施方式中，本发明的应用提供了包含第一纤维层的纤维毡，所述的第一纤维层通过将45-55wt％的合成聚合物纤维、35-45wt％的天然纤维、和5-15wt％的碳纤维组合而形成。
在本发明的另一种实施方式中，本发明提供了包含夹在第一纤维层和第二纤维层之间的芯层的纤维毡；所述第一纤维层通过将45-55wt％的合成聚合物纤维、35-45wt％的天然纤维、和5-15wt％的碳纤维组合而形成；并且所述第二纤维层通过将45-55wt％的合成聚合物纤维、35-45wt％的天然纤维、和5-15wt％的碳纤维组合而形成。
在本发明的另一种实施方式中，本发明提供了包含由纤维毡形成的模制基体的成型制品，所述纤维毡包含通过将45-55wt％的合成聚合物纤维、35-45wt％的天然纤维、和5-15wt％的碳纤维组合而形成的第一纤维层。
附图说明
本发明如上所述的和其它的特征，以及获得它们的方式，将通过参考下文结合附图描述的实施方式的说明而变得更加明显并被更好地理解，其中：
图1为根据本发明的第一纤维毡的横截面图；
图2为根据本发明的第二纤维毡的横截面图；
图3为由图1或2的纤维毡来制造成型制品的制造工艺的流程图；并且
图4为由图1或2的纤维毡来制造成型制品的另一种制造工艺的流程图。
具体实施方式
应当理解的是，本发明并不限于其在下文的说明中提出的或者在附图中描述的部件的结构和配置的细节应用。本发明在这里还可以是其它的实施方式并且能够以多种方式来实施或执行。而且，可以理解的是，在这里使用的表述和术语仅用于说明的目的，并且不应当被认为是限定，其可被本领域技术人员所理解。
现在参考附图，图1示出根据本发明的平坦的纤维毡10的第一示例性的实施方式。所示的纤维毡10包含第一纤维层12。纤维层12可特别地包含如下的不同材料组成的纤维：
·45-55wt％的纤维层12可由聚合物纤维、并且更特别是合成聚合物纤维形成。示例性的合成聚合物纤维可以包括聚丙烯纤维，其可以进一步包括一种或多种聚丙烯均聚物和/或一种或多种聚丙烯共聚物(例如聚丙烯-马来酸酐共聚物)的纤维。聚合物纤维可以具有8mm至40mm、并且更特别是12mm至25mm的长度。特别地，聚合物纤维可以具有根据ASTM D1238-13在230℃、在2.16kg负载下测得的0.1g/10min-10g/10min，并且更特别地根据ASTM D1238-13在230℃、在2.16kg负载下测得的0.6g/10min-6g/10min的熔体流动指数。
·35-45wt％的纤维层12可由天然纤维形成。示例性的天然纤维可以包括洋麻、亚麻、黄麻、大麻、剑麻和纤维素中的一种或多种。所述天然纤维可以具有8mm至40mm、并且更特别为12mm至25mm的长度；和
·5-15wt％的纤维层12可由碳纤维形成。所述碳纤维可以进一步包括新的和/或再生的碳纤维。所述碳纤维可以具有8mm至40mm，并且更特别地为12mm至25mm的长度。
特别地，纤维层12可以通过在名称为Utilization of Recycled CarbonFiber、公开号为2010/0261014的美国专利申请中公开的方法而成型为平坦片材，该申请所教导的内容在这里通过参考而被全文引入。特别地，纤维层12还可以通过干法成网非织造物(dry-laid nonwoven fabric)制造工艺，例如气流铺置(airlay)工艺而成型为平坦片材。特别地纤维层12具有500-1,000克/平方米(gsm)的单位面积重量。
在一个示例性的实施方式中，使用在公开号为2010/0261014的美国专利申请中公开的工艺来制造，具有840gsm重量的纤维层12可由如下形成：
·50％聚丙烯-马来酸酐共聚物纤维，其包含95-99wt％聚丙烯和作为聚丙烯的共聚单体的1-5wt％马来酸酐；
·40％天然纤维，其中38％为洋麻、黄麻和亚麻的组合，并且2％为纤维素纤维；和
·10％再生碳纤维。
除了纤维层12，纤维毡10还可以进一步包含特别地具有30-100gsm单位面积重量，并且更特别地具有50-75gsm的单位面积重量的非织造粗孔织品的第二和第三纤维层14、16，其分别置于第一纤维层12的相对的前侧和后侧。特别地非织造粗孔织品可由聚对苯二甲酸乙二醇酯形成，可被用于促进纤维毡10与装饰覆盖层的粘结，并促进与后续形成的肋与紧固位置的粘结，其将在下文更加详细地描述。
与不使用包含碳纤维的纤维层12的纤维毡相比，根据本发明的纤维毡10可显示如下的拉伸强度和热变形温度物理特性的提高。
注：
1.ASTM D638-10，50mm/min。
2.ASTM D648-07。
3.50％聚丙烯-马来酸酐共聚物纤维，其包含95-99wt％聚丙烯和作为聚丙烯共聚单体的1-5wt％马来酸酐。
在如图2所示的纤维毡10的第二实施方式中，纤维毡10’可包含夹在两个相对的纤维层12a、12b之间的芯层18。芯层18具有300-1,000gsm的单位面积重量和0.5至1.5mm的厚度。芯层18可以由再生毛织物、纸板、蜂窝体和聚氨酯泡沫形成。与第一实施方式相比，纤维层12a、12b分别可以具有100-600gsm的单位面积重量。
如在图3中所示，纤维毡10可用于制造成型制品70。制品70可以通过首先将位于两个相对的加热板20、22之间的纤维毡10加热至375-425℃的温度持续45-60秒的时段，或者直至纤维毡10达到400℃的温度来形成。一旦将纤维毡10充分加热，就可将纤维毡10放置在第一加热压模30的两个相对的半模32、34之间。可将压模加热至60-120℃的温度。在合成聚合物纤维可在模压下流动以形成基体40的期间，可将模具30闭合并且纤维毡10成形为基体40。基体40随后可被冷却并从压模30移除。基体40的厚度可以是0.5-2mm，并且更特别地具有1-1.5mm的厚度。
其后，可以将基体40与可为片材形式的装饰覆盖层60一起置于第二压模50的两个相对的半模52、54之间。随后，可将第二压模50闭合以压模并将装饰覆盖层60层压至基体40以形成成型制品70，而装饰覆盖层60的粘合层粘结至基体40的外部的粗孔织品层14。
装饰覆盖层60可以由聚氯乙烯(PVC)、热塑性聚氨酯(TPU)和热塑性聚烯烃(TPO)形成。装饰覆盖层可以具有0.5-2.5mm的厚度，并且更特别地可由叠置于聚氯乙烯(PVC)或聚烯烃泡沫的衬垫层的聚氯乙烯(PVC)、热塑性聚氨酯(TPU)和热塑性聚烯烃(TPO)外表层形成。装饰覆盖层可以包括具有纹理的外表面和要粘结至基体40的涂覆有粘合剂的内表面。
另外在可选的实施方式中，可以将装饰覆盖层60与纤维毡10一起引入至第一压模30中，从而一步形成制品70，这里使用单独的模具30。
在另一可选的实施方式中，应当理解的是，装饰层60并不是所必需的，并且成型制品70可以仅包含基体40。还应当理解的是，纤维毡10’可以替代为在图3的工艺中示出的纤维毡10’。
在图3的工艺的另一种可选的实施方式中，如在图4中所示的，压模30可被构建为注射-压模模具30’，其经构建以接收来自聚合物输送单元36例如用于注射-压模的注射成型机的螺杆塑化单元的树脂。这里，在纤维毡10的压模之后，聚合物输送单元36与半模34内的恰当的流道38会合，可以将聚合物材料输送至压模的基体的背面，从而模制多个沿着基体40’的长度延伸的伸长增强(加固)肋42，以及在基体40’的背面模制紧固位置(例如螺孔、鼓形罩)。
成型制品70特别地可以是机动车的装饰构件，例如内部或外部装饰面板，比如侧面装饰面板(例如门装饰面板)；杂物盘、顶篷内衬、仪表板、上部或下部仪表板封闭板、操控台、车箱内衬、门部支撑、膝挡板和座椅靠背。
虽然已描述本发明的优选实施方式，但是应当理解，各种的改变、调整和改进均可在不脱离本发明的精神和所附加的权利要求的范围的情况下做出。因此，本发明的范围不应当参考上文的说明来确定，而是应当参考所附加的权利要求以及它们等同物的全部范围来确定。此外，应当理解，所附加的权利要求并不必须包含赋予申请人要求保护的(多个)发明最宽的范围、或者仅以(多个)所述发明可要求保护的唯一(多种)方式、或者不必包括需要所有列举的特征。

Claims (27)

1.纤维毡，包含
第一纤维层，所述第一纤维层通过将45-55wt％的合成聚合物纤维、35-45wt％的天然纤维、和5-15wt％的碳纤维组合而形成。
2.权利要求1的纤维毡，其中：
所述纤维层具有500-1,000克/平方米范围的单位面积重量。
3.权利要求1的纤维毡，其中：
所述碳纤维包含新的磁纤维和再生碳纤维中的至少一种。
4.权利要求1的纤维毡，其中：
所述碳纤维具有8-40mm范围的长度。
5.权利要求1的纤维毡，其中：
所述天然纤维包含洋麻、黄麻、亚麻和纤维素纤维中的至少一种。
6.权利要求1的纤维毡，其中：
所述天然纤维具有8-40mm范围的长度。
7.权利要求1的纤维毡，其中：
所述合成聚合物纤维包含热塑性纤维。
8.权利要求1的纤维毡，其中：
所述合成聚合物纤维包含聚丙烯纤维。
9.权利要求8的纤维毡，其中：
所述聚丙烯纤维包含聚丙烯-马来酸酐共聚物。
10.权利要求1的纤维毡，其中：
所述合成聚合物纤维具有8-40mm范围的长度。
11.权利要求1的纤维毡，进一步包含
第二纤维层，位于第一纤维层的前侧上，所述笫二纤维层包含粗孔织品层，其具有30-100克/平方米范围的单位面积重量。
12.权利要求11的纤维毡，其中：
第二纤维层的纤维包含聚对苯二甲酸乙二醇酯纤维。
13.权利要求11的纤维毡，进一步包含
第三纤维层，位于笫一纤维层的后侧上，所述笫三纤维层包括具有30-100克/平方米范围的单位面积重量的粗孔织品层。
14.权利要求13的纤维毡，包括：
第三纤维层的纤维包括聚对苯二甲酸乙二醇酯纤维。
15.纤维毡，包括：
夹在第一纤维层和第二纤维层之间的芯层；
通过将45-55wt％的合成聚合物纤维、35-45wt％的天然纤维、和5-15wt％的碳纤维组合而形成的第一纤维层；和
通过将45-55wt％的合成聚合物纤维、35-45wt％的天然纤维、和5-15wt％的碳纤维组合而形成的第二纤维层。
16.权利要求15的纤维毡，其中：
第一纤维层具有100-600克/平方米范围的单位面积重量；并且
第二纤维层具有100-600克/平方米范围的单位面积重量。
17.权利要求15的纤维毡，其中：
芯层具有300-1,000克/平方米范围的单位面积重量。
18.权利要求15的纤维毡，其中：
所述芯层由聚合物泡沫、蜂窝体、纸板和金属网中的至少一种形成。
19.成型制品，包含
由纤维毡形成的模制基体，所述纤维毡包含第一纤维层，其通过结合45-55wt％的合成聚合物纤维、35-45wt％的天然纤维、和5-15wt％的碳纤维而形成。
20.权利要求19的成型制品，其中：
第一纤维层具有500-1,000克/平方米范围的单位面积重量。
21.权利要求19的成型制品，其中：
所述纤维毡包含通过将45-55wt％的合成聚合物纤维、35-45wt％的天然纤维、和5-15wt％的碳纤维组合而形成的第二纤维层。
22.权利要求21的成型制品，其中：
第一纤维层具有100-600克/平方米范围的单位面积重量；并且
第二纤维层具有100-600克/平方米范围的单位面积重量。
23.权利要求21的成型制品，进一步包含
夹在第一纤维层和第二纤维层之间的芯层。
24.权利要求23的成型制品，其中：
所述芯层具有300-1,000克/平方米范围的单位面积重量。
25.权利要求23的成型制品，其中：
所述芯层由聚合物泡沫、蜂窝体、纸板和金属网中的至少一种形成。
26.权利要求19的成型制品，进一步包含：
叠置于模制基体的装饰覆盖层。
27.权利要求26的成型制品，其中：
所述装饰覆盖层由片材形成。
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