CN110588090A - Composite panel and corresponding method - Google Patents

Composite panel and corresponding method Download PDF

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Publication number
CN110588090A
CN110588090A CN201910465812.6A CN201910465812A CN110588090A CN 110588090 A CN110588090 A CN 110588090A CN 201910465812 A CN201910465812 A CN 201910465812A CN 110588090 A CN110588090 A CN 110588090A
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CN
China
Prior art keywords
composite
composite layer
fibres
fibers
type
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201910465812.6A
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Chinese (zh)
Inventor
B·凯内尔
X·托努加西亚卡列诺
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.)
Virginia Interior Systems Co Ltd
Faurecia Innenraum Systeme GmbH
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Virginia Interior Systems Co Ltd
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Filing date
Publication date
Application filed by Virginia Interior Systems Co Ltd filed Critical Virginia Interior Systems Co Ltd
Publication of CN110588090A publication Critical patent/CN110588090A/en
Pending legal-status Critical Current

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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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/22—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
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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    • Y02W30/62—Plastics recycling; Rubber recycling

Abstract

The composite sheet (2), in particular a composite sheet, according to the invention comprises a first composite layer (4) comprising fibers belonging to a first type of fibers (14); a second composite layer (6) comprising fibers belonging to a second type of fibers (20); a third composite layer (8) comprising fibers belonging to a third type of fibers (30). The first type of fiber is a carbon fiber, the second type of fiber is a natural fiber, the first composite layer comprises a first thermoplastic binder material (16), the second composite layer comprises a second thermoplastic binder material (22), the third composite layer comprises a third thermoplastic binder material (32), and the third type of fiber is a natural fiber having an average length greater than an average length of the second type of fiber. The invention can be applied to automobile carrier plates.

Description

Composite panel and corresponding method
Technical Field
The invention relates to a composite board, in particular to a composite laminated board, which comprises:
a first composite layer comprising fibers belonging to a first type of fibers,
a second composite layer comprising fibers belonging to a second type of fibers, and
a third composite layer comprising fibers belonging to a third type of fibers.
Background
WO2017/23764 discloses a composite structure comprising three layers, wherein at least two of the layers comprise different fiber materials or different fiber contents.
Other multilayer structures are disclosed in e.g. EP 2750879, EP 2842727 and WO 2017/112632.
Disclosure of Invention
The known structures do not provide complete satisfaction, and the object of the present invention is to provide a composite panel that is relatively light weight, rigid and economical to manufacture. The composite panels according to the invention should preferably be ecological and use few resources.
The composite panel should be capable of being used in a wide range of industries, particularly the automotive industry, such as for door panels.
In order to achieve at least one of the above objects, the present invention proposes a composite panel as defined above, characterized in that:
-the first type of fibres are carbon fibres,
-the second type of fibres are natural fibres,
the first composite layer comprises a first thermoplastic binder material,
the second composite layer comprises a second thermoplastic binder material,
-the third composite layer comprises a third thermoplastic binder material and the third type of fibres are natural fibres having an average length greater than the average length of the second type of fibres.
According to a particular embodiment, the composite panel according to the invention may comprise one or more of the following features taken alone or together in all technically possible combinations:
-the first composite layer does not contain natural fibers and the second composite layer does not contain carbon fibers;
-the fibres belonging to the third type of fibres represent 40-55% by weight of the third composite layer;
-the third thermoplastic binder material comprises 35-50% by weight of the third composite layer;
the fibers belonging to the third type of fibers and the third thermoplastic binder material together comprise 85-100% by weight of the third composite layer;
-the third composite layer comprises a further thermoplastic binder material which constitutes at most 15% by weight of the third composite layer, in particular the fibres belonging to the third type of fibres, the third thermoplastic binder material and the further thermoplastic binder material constitute 100% by weight of the third composite layer;
-the further thermoplastic adhesive material is different from the third thermoplastic adhesive material, in particular, the third thermoplastic adhesive material is polypropylene (PP) and the further thermoplastic adhesive material is a polyester, such as PET;
-the first, third and/or further thermoplastic binder material is in the form of fibres before laminating the first, second and third composite layers,
the first and second thermoplastic binder materials comprise, and especially consist of, polypropylene (PP), and
-the first type of fibers are recycled fibers and/or the second type of fibers are recycled fibers.
The invention also relates to a method for producing a composite panel as defined above, comprising the following steps:
-providing a precursor of the first composite layer,
-providing a precursor of the second composite layer,
-providing a precursor of the third composite layer,
-stacking the precursors of the first, second and third composite layers one on top of the other such that the precursor of the second composite layer is located between the precursor of the first composite layer and the precursor of the third composite layer,
-laminating the precursors of the first, second and third composite layers to each other by heating said composite layers above the melting point of at least one of said thermoplastic binder materials, and
-cooling the heated precursor of the first, second and third composite layers.
According to one embodiment of the method, the precursor of the second composite layer comprises a recycled composite comprising natural fibers and a thermoplastic binder material.
Within the scope of the present patent application, the various aspects, embodiments, examples, features and alternatives set forth in the preceding paragraphs, in the claims and/or in the following description and drawings may be employed independently or in any combination thereof. For example, features disclosed in connection with one embodiment may be applicable to all embodiments unless there is a technical incompatibility of the features. Moreover, for any combination of disclosed features, it is contemplated that the features can also be separated and used individually, or as any possible subset of the combination of features.
Drawings
The invention will be better understood from the following description with reference to the accompanying drawings, which show:
figure 1 is a schematic cross-sectional view of a composite plate according to a first embodiment of the invention;
figure 2 is a schematic cross-sectional view of a composite plate according to a second embodiment of the invention;
FIG. 3 is a schematic view of an apparatus for producing components of a composite panel according to the invention, and
figure 4 is a schematic view of a plant for producing composite panels according to the invention.
Detailed Description
Fig. 1 shows, in cross-section, a composite plate according to a first embodiment of the invention, which is designated by the general reference numeral 2.
The composite panel 2 is in particular a composite laminate.
The composite panel 2 comprises a first composite layer 4, also referred to as upper layer, a second composite layer 6, also referred to as intermediate layer, and a third composite layer 8, also referred to as lower layer. The composite panel 2 comprises a first surface 10 and a second surface 12. The first surface 10 is formed by the first composite layer 4 in this embodiment and may be what is commonly referred to as an "a-surface", meaning that the first surface 10 may be the visible surface in use of the panel. In some embodiments, the first surface may be covered by a decorative layer forming the visible surface of the panel.
The first composite layer 4 is bonded to the second composite layer 6, and the second composite layer 6 is bonded to the third composite layer 8 such that the second composite layer 6 is disposed between the first composite layer 4 and the third composite layer 8. The first composite layer 4 comprises fibers belonging to the first type of fibers 14 and a first thermoplastic binder material 16. The first thermoplastic binder material 16 is advantageously in the form of fibers, especially fibers prior to lamination of the first, second and third layers. Before lamination means that the layers are made by using thermoplastic fibres which will melt or partially melt during the production of the layers or in a subsequent step during the lamination process leading to the composite panel. The first thermoplastic adhesive material 16 may comprise polypropylene (PP), and may in particular consist of polypropylene. The expression "consisting of polypropylene" does not exclude that the polypropylene comprises additives commonly used for commercially available polypropylenes, such as processing agents and pigments. These possible additives are present only in trace amounts, for example up to 5% by weight of the polypropylene material. According to a variant, the first thermoplastic binder material 16 may comprise or may consist of a further thermoplastic material, such as a further polyolefin. The first composite layer 4 is a nonwoven and may be a fleece fabric.
In the present embodiment, the first composite layer 4 is composed of fibers belonging to the first type of fibers 14 and a first thermoplastic binder material 16.
Preferably, the first type of fibers 14 are recycled fibers. According to the invention, the first type of fibres are carbon fibres. More specifically, the composite sheet 2 thus comprises recycled carbon fibres in the first composite layer 4. The composite plate 2 is therefore particularly economical. The recycled carbon fibers may be carbon fibers that have had their sizing removed and are therefore free of sizing. In general, however, the carbon fibers may be woven, non-woven, or unidirectionally oriented fibers.
The fibers belonging to the first type of fibers 14 in the first composite layer 4 may constitute up to 90% by weight of the first composite layer 4, but advantageously 40-60% by weight, and the first thermoplastic binder material 16 advantageously 40-60% by weight of the first composite layer 4.
The first composite layer 4 may further comprise an optional bonding agent (not shown) adapted to increase the adhesion of the fibers belonging to the first type of fibers 14 to the first thermoplastic binder material 16. Thus, optionally, the first composite layer 4 consists of fibers belonging to the first type of fibers 14, a first thermoplastic binder material 16 and optionally a bonding agent. The bonding agent is, for example, maleic anhydride, and is, among other things, grafted onto the first thermoplastic binder material 16 or otherwise added to or to the binder. In particular, the first thermoplastic binder material 16 in the form of fibers has a bonding agent grafted onto the surface of the fibers. Preferably, the binding agent is grafted to the binder material prior to cutting the binder material into fibers.
The carbon fibres of the first composite layer 4 have a length of, for example, 10mm to 200mm, more preferably 40mm to 120mm, and a diameter of 3 microns to 25 microns, preferably 5 microns to 15 microns.
The surface weight of the first composite layer 4 is 75 to 125 g/m2E.g. 100 g/m2. The first composite layer 4 may have a thickness of 0.05mm to 1.0mm, preferably 0.1mm to 0.6 mm.
The second composite layer 6 comprises fibers belonging to the second type of fibers 20 and a second thermoplastic binder material 22. The second thermoplastic adhesive material 22 may comprise the same polymeric material as the first thermoplastic adhesive material 16.
Advantageously, the second thermoplastic binder material 22 is a recycled material. The second thermoplastic adhesive material 22 comprises, and in particular consists of, polypropylene (PP). Alternatively still, the second thermoplastic binder material may comprise or consist of other thermoplastic materials such as additional polyolefins. The second composite layer 6 comprises short fibers.
The second type of fibers are natural fibers. The natural fibers are, for example, bast fibers, such as hemp, flax, kenaf or jute. The natural fibers may also be wood fibers, preferably softwood fibers, such as coniferous fibers.
The surface weight of the second composite layer 6 is, for example, 400 to 900 g/m2. Preferably, the surface weight of the second composite layer 6 is 500 to 800 g/m2E.g. 600 g/m2. The second composite layer 6 may have a thickness of 0.4mm to 4.0mm, preferably 0.6mm to 3.0 mm.
The second composite layer 6 is advantageously composed of fibers belonging to the second type of fibers 20 and a second thermoplastic binder material 22. Further advantageously, the second type of fibers are recycled fibers. More advantageously, the second composite layer 6 may comprise a recycled composite, such as a ground composite. In particular, waste from the production of natural fiber composite panels is advantageous for recycling composite materials. Pellets of such recycled composite material typically have a size of 0.1mm to 3 mm. Thus, the length of the fibers in the recycled material is typically up to 0.1mm to 3 mm. The fibers belonging to the second type of fibers 20 have an average length of 0.05mm to 4.0 mm.
The third composite layer 8 comprises fibers belonging to a third type of fibers 30 and a third thermoplastic binder material 32.
The fibres belonging to the third type of fibres 30 are natural fibres and represent 40 to 55% by weight of the third composite layer 8. The natural fibers are, for example, bast fibers such as hemp, flax, kenaf or jute. Bast fibers typically have a bundle diameter of 25 to 200 microns, preferably 50 to 100 microns. The length of the bast fibre bundles is typically 30mm to 150mm, preferably 40mm to 120 mm. The natural fibers may also be wood fibers, preferably softwood fibers, such as coniferous fibers. Typically, the wood fibers have a diameter of 25 to 300 micrometers, preferably 50 to 200 micrometers. The length of the wood fibers is typically 5mm to 15mm, preferably 9mm to 12 mm. The average length of the third type of fibers is typically greater than 5mm, and in some embodiments greater than 10 mm. The difference between the natural fibers of the second type of fibers and the natural fibers of the third type of fibers is that the recycled fibers in the second composite are shorter than the virgin fibers in the third layer. Thus, even if the natural fibers in the second composite layer are of similar origin and of similar chemical composition, their lengths will be shorter due to the recycling process.
The surface weight of the third composite layer 8 is, for example, 400 to 900 g/m2. Preferably, the surface weight of the second composite layer 8 is 500 to 800 g/m2E.g. 600 g/m2. The third thermoplastic adhesive material 32 comprises 35-50% by weight of the third composite layer 8. The fibers belonging to the third type of fibers 30 and the third thermoplastic binder material 32 together make up 85-100% by weight of the third composite layer 8. Any of the first, second, or third thermoplastic binder materials may include additives, for example, to improve processing and/or aging properties. Any one, several or all of the first, second and third thermoplastic binder materials may comprise additives such as one or more processing agents, colorants or pigments and/or adhesion promoters for the fibers of the respective layers.
The third composite layer 8 may comprise a further thermoplastic binder material which constitutes at most 15% by weight of the third composite layer. In particular, the further thermoplastic adhesive material constitutes 1% by weight or more of the third composite layer 8, and in particular 8-12% by weight of the third composite layer. Advantageously, the fibres belonging to the third type of fibres 30, the third thermoplastic binder material 32 and the further thermoplastic binder material 34 together make up 100% by weight of the third composite layer 8. In other words, the third composite layer 8 is composed or consists only of the fibres belonging to the third type of fibres, the third thermoplastic binder material and the further thermoplastic binder material 34.
The natural fibers of the third type of fibers 30 are for example selected from the same type of fibers as the second type of fibers. Typically, the length of the natural fibres is from 30mm to 150mm for bast fibres and from 5mm to 15mm, preferably from 9mm to 12mm for wood fibres. The length of these natural fibres is greater than the length of the fibres in the second composite layer 6. More specifically, the second type of fibers 20 are fibers having an average length that is less than the average length of the third type of fibers 30.
Advantageously, the natural fibers of the third type of fibers 30 are identical to the natural fibers of the second type of fibers 20 except for their length. In one embodiment, the third layer of composite material is made of virgin material and the second layer is made of similar or identical but recycled material.
The further thermoplastic adhesive material 34 is different from the third thermoplastic adhesive material and is in particular polyester and advantageously polyethylene terephthalate (PET). The third thermoplastic adhesive material may be polypropylene.
The third and/or further thermoplastic binder material 32, 34 may be in the form of fibers, especially prior to lamination.
The surface weight of the third composite layer 8 is, for example, 100 to 600 g/m2. The third composite layer 8 may have a thickness of 0.3mm to 3 mm.
Fig. 2 shows a schematic cross-sectional view of a composite plate according to a second embodiment of the invention. The embodiment according to fig. 2 differs from the embodiment of fig. 1 only in the following. Elements similar to those of the first embodiment are given the same reference numerals as those of the first embodiment.
The third composite layer 8 does not contain an additional thermoplastic binder. The third composite layer 8 may be the same as the first composite layer 4.
In fig. 3, an apparatus for producing a component of a composite panel according to the invention is shown. More specifically, fig. 3 schematically shows the production steps of the precursor material 50 of the second composite layer 6 with the precursor production apparatus 100.
The precursor material 50 comprises fibers belonging to the second type of fibers 20 and the second thermoplastic binder material 22. In particular, the precursor material is agglomerated particles 52 comprising fibers belonging to the second type of fibers 20 and the second thermoplastic binder material 22.
The precursor production plant 100 includes a waste inlet 102, a pre-cutting station 104, an agglomeration station 106, a grinding station 108, a sizing station 110, and an outlet station 112.
Production of the precursor material 50 begins at a waste inlet 102, where a waste element 120 comprising the second thermoplastic binder material and the fibers belonging to the second type of fibers is introduced at the waste inlet 102. Here, the expression "fibres of the second type" is used for fibres made of the same material as the fibres belonging to the second type, but their length may be greater than the fibres in the second composite layer of the composite board. The scrap element is, for example, an element resulting from the production of a natural fiber composite board, or the scrap element is a part at the end of its service life and has a minimum dimension of 10cm to 1 m. Scrap elements 120 are cut into smaller elements 122 by pre-cutting station 104. The smaller elements have a minimum dimension of, for example, 5cm to 10 cm. The smaller elements 122 are then agglomerated at the agglomeration station 106 and introduced into the grinding station 108. In the grinding station 108, the smaller elements 122 are ground into ground particles 124 having a size of 5mm to 7 mm. The ground particles 124 are then sieved at the sieving station 110 and agglomerated particles 52 are obtained.
The precursor material 50 is then collected in a container.
Fig. 4 shows a schematic view of a panel production plant 200 for producing a composite panel 2 according to the invention.
The board production apparatus 200 includes:
a first precursor source 202 adapted to provide a precursor material 204 of the first composite layer 4, such as a first composite web,
a second precursor source 206 adapted to provide a precursor material 50 of the second composite layer 6,
a third precursor source 210 adapted to provide a precursor material 212 of a third composite layer 8, such as a third composite web,
a drying station 214, such as an infrared heater, adapted to dry the precursor material 50 provided by the second precursor source 206, and
-joining means 220 adapted to join the precursor material 204 of the first composite layer 4, the precursor material 50 of the second composite layer 6 and the precursor material 212 of the third composite layer 8 to obtain a composite web 222,
an accumulation device 224 of the composite web 222, and
a cutting device 226 adapted to cut the composite web 222 into composite panels 2.
The splicing device 220 includes a calendaring unit 230, a laminating device 232 including an upper tape 234 and a lower tape 236. The lamination apparatus 232 further comprises a heating section 238 and a cooling section 240. The lamination device may also be configured as a needling device in which the first, second, and third composite layers are needled together.
The composite panel 2 according to the invention is produced in the following way:
the precursor material 50 is disposed on the precursor material 212 of the first composite layer 4 and is subsequently dried using a drying station 214. The precursor material 204 of the third composite layer 8 is arranged on the dried precursor material 50 and the three precursor materials 212, 50 and 204 are introduced into the bonding means 220.
The three introduced precursor materials 204, 212, and 50 are calendered by calendering unit 230.
The three calendered precursor materials 204, 212, and 50 are heated to a temperature above the melting temperature of the thermoplastic binder material by the heating section 238 and pressed together while the thermoplastic binder material is in a molten state. The three precursor materials 204, 212, and 50 are then cooled until the thermoplastic binder material solidifies, thereby obtaining the composite web 222.
The composite web 222 is then cut into composite panels 2 by a cutting station 226.
The composite panel 2 according to the invention is advantageous because it is economically produced due to the recycled fibers and thermoplastic binder material. The composite plate 2 is also relatively rigid for a given thickness due to its structure and is easy to use in another manufacturing process.
In an alternative embodiment, the precursor of the second composite layer is a sandwich layer, wherein the recycled material forms a central layer which is covered on both sides with a thermoplastic film, for example a polypropylene film. The method of producing such a precursor may be similar to that shown in fig. 4. In this case, the recycled material is disposed between the two thermoplastic films 202, 212. The advantage of this embodiment is that the precursor is coherent, in contrast to granular precursors. The sandwich layer is laminated with the first and second composite layers.

Claims (15)

1. Composite panel (2) comprising:
a first composite layer (4) comprising fibres belonging to a first type of fibres (14),
a second composite layer (6) comprising fibres belonging to a second type of fibres (20), and
a third composite layer (8) comprising fibers belonging to a third type of fibers (30),
the method is characterized in that:
-the first type of fibres are carbon fibres,
-the second type of fibres are natural fibres,
-the first composite layer comprises a first thermoplastic binder material (16),
-the second composite layer comprises a second thermoplastic binder material (22),
-the third composite layer comprises a third thermoplastic binder material (32), and the third type of fibres are natural fibres having an average length greater than the average length of the second type of fibres.
2. The composite panel according to claim 1, wherein the first composite layer does not contain natural fibers and the second composite layer does not contain carbon fibers.
3. The composite panel of claim 2, wherein
-the fibres belonging to the third type of fibres represent 40-55% by weight of the third composite layer (8),
-the third thermoplastic adhesive material (32) constitutes 35-50% by weight of the third composite layer (8),
the fibers belonging to the third type of fibers (30) and the third thermoplastic binder material (32) together constitute 85-100% by weight of the third composite layer.
4. A composite board according to claim 2 or 3, wherein
The third composite layer (8) comprises a further thermoplastic binder material (34) which constitutes at most 15% by weight of the third composite layer.
5. A composite board according to claim 4, wherein the fibres belonging to the third type of fibres, the third thermoplastic binder material and the further thermoplastic binder material constitute 100% by weight of the third composite layer.
6. The composite panel of claim 4, wherein
The additional thermoplastic binder material (34) is different from the third thermoplastic binder material.
7. A composite panel according to claim 6, wherein the third thermoplastic binder material is polypropylene (PP) and the further thermoplastic binder material is polyester.
8. The composite panel according to claim 7, wherein the polyester is PET.
9. A composite board according to any one of claims 1-3, wherein one, more or all of the group consisting of the first, third and further thermoplastic binder materials (16, 22, 32, 34) are in the form of fibres before the first, second and third composite layers are laminated.
10. A composite board according to any one of claims 1-3, wherein the first and second thermoplastic binder materials (16, 22) comprise polypropylene (PP).
11. A composite panel according to claim 10, wherein the first and second thermoplastic binder materials (16, 22) are comprised of polypropylene.
12. A composite board according to any of claims 1-3, wherein one or both of the group consisting of the first type of fibres and the second type of fibres are recycled fibres.
13. A composite board according to any one of claims 1-3, wherein the composite board is a composite laminate board.
14. A method of producing a composite panel according to any of claims 1 to 13, the method comprising the steps of:
-providing a precursor of the first composite layer (4),
-providing a precursor of the second composite layer (6),
-providing a precursor of the third composite layer (8),
-stacking the precursors of the first, second and third composite layers one on top of the other such that the precursor of the second composite layer is located between the precursor of the first composite layer and the precursor of the third composite layer,
-laminating the precursors of the first, second and third composite layers to each other by heating said composite layers above the melting point of at least one of said thermoplastic binder materials, and
-cooling the heated precursor of the first, second and third composite layers.
15. The method of claim 14, wherein the precursor of the second composite layer comprises a recycled composite comprising natural fibers and a thermoplastic binder material.
CN201910465812.6A 2018-06-11 2019-05-31 Composite panel and corresponding method Pending CN110588090A (en)

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US20040235376A1 (en) * 2003-05-19 2004-11-25 Byma George B. Vehicle interior trim component containing carbon fibers and method of manufacturing the same
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US20070269645A1 (en) * 2006-04-05 2007-11-22 Venkat Raghavendran Lightweight thermoplastic composite including reinforcing skins
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