CN105934316B - 纤维复合材料及其生产方法 - Google Patents

纤维复合材料及其生产方法 Download PDF

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CN105934316B
CN105934316B CN201480072681.0A CN201480072681A CN105934316B CN 105934316 B CN105934316 B CN 105934316B CN 201480072681 A CN201480072681 A CN 201480072681A CN 105934316 B CN105934316 B CN 105934316B
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filaments
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fibres
tape
yarns
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C·维埃特
A·弗拉什耐克尔
V·赛亚克
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
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    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
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    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
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    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
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    • B32—LAYERED PRODUCTS
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • 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
    • B32B5/00—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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/12—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 structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
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    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • 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
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B29K2067/003—PET, i.e. poylethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0809—Fabrics
    • B29K2105/0845—Woven fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2307/00—Use of elements other than metals as reinforcement
    • B29K2307/04—Carbon
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
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    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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  • Mechanical Engineering (AREA)
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  • Composite Materials (AREA)
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Abstract

本发明涉及纤维复合材料，其含有一层或多层的增强纤维或增强长丝，并含有与之连接的一层或多层条带纱；还涉及其生产方法。

Description

纤维复合材料及其生产方法
描述
本发明涉及纤维基质中间体(也称为“粗纱”)及其生产方法。本发明尤其涉及纤维基质中间体，其用于生产具有热塑性基质的纤维复合材料。由这些中间体制备的产品可以例如是有机片材，其目前主要用于汽车和飞机结构中。其它潜在应用是生产前端部件、座椅、载体和踏板。
有机片材是纤维基质中间体。它们由连续纤维制成的织造织物或平纹织物构，被包埋在热塑性基质中。热塑性基质的优势在于高的自动化潜力，例如中间体的连续生产和热成型性，以及与常规热固性纤维复合材料相比的短加工时间。这尤其在具有短加工时间的汽车工业中受到极大关注。这里通常使用的纤维材料是玻璃、芳族聚酰胺和碳。在织造织物和平纹织物中，纤维也可以彼此按照直角运行，从而可以具有比其金属原型更好的机械性能，例如刚度、强度和热膨胀性。与金属片材相比，拉伸和压缩行为不是对称的。
高强度热塑性纤维复合材料通常通过首先使得一束连续长丝、例如碳纤维、芳族聚酰胺纤维或玻璃纤维作为增强纤维铺置制备。然后，将由热塑性粘合剂材料例如聚酰胺树脂、热塑性聚氨酯或聚酯构成的基质材料的浆料涂布在增强纤维之上和/或之下。然后通过加热和可能施加压力使得基质材料熔融，从而得到纤维复合材料。例如，WO 2005/033390A2公开了这种方法。
可交联的材料和相似材料的基质材料也当然是常见的，是本领域技术人员公知的。
混杂的纤维复合材料也可以用作有机片材，其中除了增强长丝之外，还引入其它长丝作为基质材料。长丝优选沿着单向取向；这可以例如通过使用合适的引导装置和纱线引导设备分离长丝进行。再次，最后施涂基质材料或固定试剂，从而以加热或化学方式生产复合材料。
生产混杂纤维复合材料的现有技术方法的缺点是有时难以实现基质材料的均匀施涂。另外，通常必须分离或分布不同类型的长丝，这些长丝的不同机械性能会引起问题。
本发明解决了此问题，因为本发明提供了一种纤维复合材料，其含有一层或多层的增强纤维或长丝以及与之接触的一层或多层条带纱。
在本发明中，术语“条带纱(ribbon yarn)”理解为表示单向取向长丝的分布排列，其中宽度：厚度的比率是至少10:1，优选50:1，更优选40:1，最优选30:1，例如厚度为0.2mm和宽度为6mm。这种排列是通过合适的粘合剂固定的，例如浆料或热塑性粘合剂。
用于条带纱的材料优选是在WO2013/117728中描述的那些。这些材料的主要优点是处理简单，基质材料的分布特别均匀，能实现短的固结路径，并得到非常均匀的产物。在无扭绞情况下卷绕的条带纱可以例如易于运输和在现场使用。
对于本发明的纤维复合材料，优选的是，至少一层的增强纤维或增强长丝位于两层条带纱之间。这种夹心结构导致形成非常均匀的中间体，其可以容易且便宜地进一步在随后步骤中加工。
所以，本发明纤维复合材料的条带纱优选含有以下物质的纱线：聚酰胺6，聚酰胺6,6，聚酯，聚对苯二甲酸乙二酯，或聚丙烯。这些优选的条带纱例如以商品名Enka TecTape由PHP Fibers,Obernburg(德国)销售。
当然，条带纱也可以由其它材料制成。可以和也优选的是，例如条带纱是由通常用作增强纤维或长丝的材料制成。例如，条带纱可以由玻璃复丝纱制成，其中长丝也在此方法中基本上彼此平行地分布和引入。这些玻璃复丝方便地使用合适的浆料固定，优选由具有线密度为12000 dtex f 2000的复丝纱构成，也优选是经过粘合活化的。因此，本发明也涉及纤维复合材料，其中增强纤维或增强长丝也是条带纱的形式。
另外，本发明涉及一种生产纤维复合材料的方法，其特征在于使得一层或多层的增强纤维或长丝与一层或多层条带纱接触。
在这里优选的是，这些条带纱的层从一个或多个卷线筒展卷。在另一个优选实施方案中，增强长丝本身也是条带纱的形式。
以此方式得到的纤维复合材料可以然后在加热和/或压力下固结，从而然后例如作为所谓的有机片材进行进一步加工。
在另一个优选实施方案中，多层的增强纤维和长丝是与多层的条带纱一起扭绞的，从而即使在没有热处理或压力的情况下也能结合。当然理想的是，所有层、即包括用于形成增强层的纤维或长丝的层也是条带纱的形式。
本发明还涉及生产纤维复合材料的方法，此方法在权利要求6-11中更详细地描述。
另外，将通过以下实施例更详细地描述本发明，但是这些实施例并不限制本发明。
实施例1
条带纱是从公称线密度为1880 dtex f280的聚酰胺6复丝生产的，如WO2013/117728所述。此方法包括以下步骤，并且也通过在附图中的示意图解释。
-纱线的展卷
-可能洗涤
-干燥
-分布
-施涂5重量％的来自EMS-Chemie AG的粘合剂Griltex 2A(在含水分散体中的共聚酰胺)
-将共聚酰胺在窑中于120℃固结
-以无扭绞方式卷绕。
实施例2
重复进行实施例1，不同之处是代替聚酰胺6，使用线密度为12000 dtex f2000的玻璃复丝纱(经过粘合活化的)。
施涂5重量％的来自EMS-Chemie AG的粘合剂Griltex 2A(在含水分散体中的共聚酰胺)或2重量％的浆料。
实施例3
使得从上述实施例制得的条带纱进行以下处理以生产纤维复合材料(在这种情况下是玻璃纤维混合粗纱)：
a)一层聚酰胺6条带纱和一层玻璃复丝条带纱；
b)作为多层制备(三层夹心)：
一层聚酰胺6条带纱(顶部)，一层玻璃复丝条带纱(中间)和一层聚酰胺6条带纱(底部)。
c)作为多层制备(五层双夹心)：
一层聚酰胺6条带纱(顶部)，然后是一层玻璃复丝条带纱和一层聚酰胺6条带纱，再然后是一层玻璃复丝条带纱，最后是一层聚酰胺6条带纱(底部)。
上述玻璃纤维混合粗纱使用共聚酰胺和/或浆料粘合(预固定)。所得的粗纱以无扭绞方式卷绕。
或者，这些层在窑中仅仅在约120℃下加热，使得共聚纤维轻微熔融，然后将这些层用辊筒(压延机)一起压制而固结，并且以无扭绞方式卷绕。

Claims (10)

1.一种纤维复合材料，其含有一层或多层的增强纤维或长丝以及与之接触的至少两层条带纱，并且一层或多层的增强纤维或长丝和至少两层条带纱在加热和/或压力下固结，其中条带纱是单向取向长丝的分布排列，其中宽度：厚度的比率是至少10:1，其中至少一层的增强纤维或长丝位于两层条带纱之间。
2.根据权利要求1的纤维复合材料，其特征在于增强纤维或长丝是选自碳纤维、玻璃纤维、玄武岩纤维和/或芳族聚酰胺纤维。
3.根据权利要求1的纤维复合材料，其特征在于条带纱的纱线是以下物质的纱线：脂族聚酰胺例如聚酰胺6、聚酰胺6,6、聚酰胺4,6，芳族聚酰胺例如PPA，聚酯例如聚对苯二甲酸乙二酯，或聚丙烯。
4.根据权利要求2或3的纤维复合材料，其特征在于增强纤维或长丝也是条带纱的形式。
5.一种生产纤维复合材料的方法，其特征在于使得一层或多层的增强纤维或长丝与至少两层的条带纱接触，并且一层或多层的增强纤维或长丝和至少两层条带纱在加热和/或压力下固结，其中条带纱是单向取向长丝的分布排列，其中宽度：厚度的比率是至少10:1，其中至少一层的增强纤维或长丝位于两层条带纱之间。
6.根据权利要求5的方法，其特征在于条带纱基本上由聚酰胺6或聚丙烯纱线组成。
7.根据权利要求5或6的方法，其特征在于多层条带纱以无扭绞方式从一个或多个卷线筒展卷。
8.根据权利要求5或6的方法，其特征在于增强纤维或长丝也作为条带纱层引入。
9.根据权利要求5或6的方法，其特征在于增强纤维或长丝的层是通过扭绞在一起而固结的。
10.根据权利要求5或6的方法，其特征在于增强纤维或长丝是选自碳纤维、玻璃纤维、玄武岩纤维和芳族聚酰胺纤维。
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