CN112203831A - 具有至少两个0°层的多轴产品 - Google Patents

具有至少两个0°层的多轴产品 Download PDF

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CN112203831A
CN112203831A CN201980036852.7A CN201980036852A CN112203831A CN 112203831 A CN112203831 A CN 112203831A CN 201980036852 A CN201980036852 A CN 201980036852A CN 112203831 A CN112203831 A CN 112203831A
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multiaxial product
multiaxial
layers
product according
nonwoven
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CN112203831B (zh
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R·沃卡茨
J·雷拜因
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Imperial Carbon Fiber Europe Ltd
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Imperial Carbon Fiber Europe Ltd
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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
    • B32B5/08—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 the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • 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
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • B29C70/228—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure the structure being stacked in parallel layers with fibres of adjacent layers crossing at substantial angles
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    • 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
    • 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
    • B32B5/26—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 another layer next to it also being fibrous or filamentary
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    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/08—Interconnection of layers by mechanical means
    • B32B7/09—Interconnection of layers by mechanical means by stitching, needling or sewing
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Nonwoven Fabrics (AREA)
  • Reinforced Plastic Materials (AREA)
  • Woven Fabrics (AREA)
  • Laminated Bodies (AREA)

Abstract

本发明涉及一种多轴产品，其包括至少三个线层，其中每个线层由复丝增强纱形成，所述复丝增强纱在线层内布置成相互平行并彼此相邻，其中至少两个线层在多轴产品内布置使得在多轴产品内定义一个0°方向，并且其中至少一个其他线层相对于多轴产品内的0°方向以大于±10°的角度布置，其中基于多轴产品内所述至少三个线层的相对布置，在0°方向上的至少两个线层直接一个接着一个，其间没有其他复丝增强纱层。本发明还涉及一种生产多轴产品的方法。本发明还涉及一种由多轴产品生产的复合物以及由多轴产品生产该复合物的方法。

Description

具有至少两个0°层的多轴产品
描述
本发明涉及一种包括至少三个线层(thread layers)的多轴产品。
多轴产品早已为人所知。
例如，EP 2547816或EP 2547510描述了多轴产品，其中在多轴产品内具有多个彼此角度不同的层。
然而，已知的多轴产品的一个缺点是，多轴产品的机械性能只能在小程度上调整。例如，多轴产品在0°方向上的压力应用强烈依赖于0°方向上线层的表面重量。表面重量的增加将导致机械性能的改善。但是，表面重量的增加不可能没有问题。高表面重量经常导致纤维偏差或纤维在层内凝结(所谓的起伏)，其结果是线层或其邻近层包含波纹。该波纹又降低了线层的机械性能。
从EP 3023241中已知一种纤维增强材料，它可以由带状材料构成，并且其不同的层以相互成角度的方式布置。根据该文件，提供了彼此间隔排列的带(它们形成分离通道)。因此，材料的机械性能受到影响，因为产生了无纱区域。
因此，本发明的任务是提供一种可以更好地适应机械性能的多轴产品。
这个任务通过一种具有至少三个线层的多轴产品来解决，其中每个线层由复丝增强纱形成，所述复丝增强纱在线层内布置成相互平行并且彼此相邻。其中至少两个线层被布置在多轴产品内，使得它们在多轴产品内定义一个0°方向，并且其中至少一个其他线层相对于多轴产品内的0°方向以大于±10°的角度布置，其中基于多轴产品内所述至少三个线层的相对布置，0°方向上的至少两个线层直接一个接着一个，而其间没有其他复丝增强纱层。
通过使用在0°方向上的至少两个线层，其在多轴产品内直接一个接一个地布置(其间没有任何其他复丝增强纱层作为线层)，可以有利地影响多轴产品的机械性能。例如，在0°方向上的至少两个线层可以由不同的复丝增强纱构成，其中不同的纱类型不能够或仅能够在很小的程度上相互产生负面影响，因为它们不存在于一个层内。
在多轴产品内与0°方向的角度大于±10°的至少一个其他线层优选具有与多轴产品内0°方向的角度为±30°、±45°、±60°和/或90°。然而，与0°方向的角度大于±10°的至少一个其他线层并不是实际意欲在0°方向上布置而只是由于不精确的原因才以稍微偏离0°方向的角度布置的线层。在下文中，将在与0°方向的角度大于±10°的至少一个其他线层也仅描述为至少一个其他线层。
为了澄清的目的：多轴产品可以包括由复丝增强纱制成的多个线层。然而，根据本发明，在形成0°层的至少两个线层之间没有由复丝增强纱制成的、与0°层的角度至少为±10°的线层(即也没有其他线层)。因此，在0°方向的线层之间，能够只存在所谓的中间层，例如非织造层。在这方面，具有强度小于2000MPa的纤维和/或在层内的主要非平行纤维排列的每个层(例如非织造物，随机取向的纤维层)应被视为中间层。
线层优选由铺展的复丝增强纱组成，其也可描述为带。带优选具有80至800毫米的宽度，特别优选带的宽度在250至360毫米之间，最特别优选600至700毫米。为了生产线层，布置铺展的复丝维增强纱，使线层内基本上没有孔(无纱区域)。结果，复丝维增强纱以无孔的方式彼此放在一起。在另一个优选的实施方案中，该至少三个线层分别由一种单向织物组成。在单向织物中，复丝增强纱也是铺展地、相互平行地和彼此相邻地布置，但是为了增加各层的稳定性，却与辅助纱交织在一起。作为辅助纱，例如可以使用纤度为200dtex的双组分热熔胶纱。
优选地，在0°方向上的至少两个线层在多轴产品内彼此直接接触。这里的“直接接触”应该是指多轴产品内0°方向上的至少两个线层相互靠在一起，而在0°方向上的至少两个线层之间没有任何其他中间层(也没有非织造物)。
优选地，在0°方向上的至少两个线层在每种情况下都具有至少100g/m2的表面重量，更优选地至少150g/m2，特别优选地至少180g/m2。在一个优选的实施方案中，0°方向上的所有线层具有相同的表面重量。然而，也可以设想0°方向上的至少两个线层具有不同的表面重量。由于在0°方向上的至少两个线层被用于多轴产品，有利的是可以在0°方向上实现高表面重量，从而例如增加了0°方向上的抗压强度。然而，与使用具有高表面重量的一个单层相比，其优点在于，例如在0°方向上的各个线层或它们的相邻层中不发生或仅发生轻微的线起伏。
优选地，至少一个其他线层的表面重量为至少100g/m2，特别优选为至少120g/m2。当使用多个这样的其他线层时，所有线层在每种情况下可以具有相同的表面重量，或者具有不同的表面重量。
优选地，该至少三个线层具有作为复丝增强线的碳纤维、玻璃纤维、芳纶纱和/或高延伸UHMW-聚乙烯纱或上述纱的混合物。特别优选的是，该至少三个线层由高达至少90％的所述纤维或纱或者所述纤维或纱的混合物组成。
在一个优选的实施方案中，0°方向上的至少两个线层具有与至少一个其他线层相同的纤维类型或纱类型。不同的线层在采用的纱纤度方面可以相同或不同。
优选的是，复丝增强纱是碳纤维纱，其强度根据JIS-R-7608测量为至少5000MPa，张力模量根据JIS-R-7608测量为至少260GPa。关于所采用的这种碳纤维纱，可参考尚未公布的日本申请，文件号为JP 2017-231749。进一步优选的是，该复丝维增强纱是碳纤维纱，其强度根据JIS-R-7608测量为至少4500MPa，张力模量根据JIS-R-7608测量为至少240GPa。
优选的是，多轴产品具有至少一个非织造层。优选地，至少一个非织造物布置在该至少三个线层上、下面和/或之间。特别优选的是，在各线层之间布置一个非织造物和/或多轴产品在每个情况下在顶侧和/或在底侧具有另一个非织造物。在这方面，应该清楚的是，非织造物也可以布置在0°方向的两个线层之间，基于该至少三个线层的相对布置，它们直接一个接着一个(在多轴产品内)，(除了在其中0°方向的线层直接相互接触的实施例中)。进一步优选的是，多轴产品具有粉末粘结剂。例如，非织造物可以具有粉末粘结剂。优选地，至少一个非织造物的表面重量为3-25g/m2。在具有多于一个非织造物的实施方案中，所有使用的非织造层可以具有相同的表面重量或不同的表面重量。一个特别优选的多轴产品的结构结果如下：
-至少一个其他线层
-非织造物
-至少一个其他线层
-非织造物
-0°方向的线层
-非织造物
-0°方向的线层
-具有粉末粘结剂的非织造物
在一个实施方案中，多轴产品具有金属网。优选地，金属网布置在至少三个线层上和/或下面。优选地，金属网形成多轴产品的最外层。特别优选的是，金属网的表面重量为50至250g/m2，特别优选为70至175g/m2，最特别优选为90至139g/m2。金属网优选与一个或多个线层连接，例如通过缝合或通过将多轴产品固定在一起的针织线系统。通过金属网，可以有利地改善多轴产品的传导性，这对于航空和空间旅行领域的应用特别有利。优选地，金属网为铜网。
优选地，至少一种非织造物由至少一种第一和一种第二热塑性聚合物组分组成，其中第一和第二聚合物组分具有不同的熔化温度。
优选地，具有较低熔化温度的聚合物组分具有80-135℃的熔化温度，和/或具有较高熔化温度的聚合物组分具有140-250℃的熔化温度。
优选地，第一聚合物组分可溶于环氧树脂、氰酸酯或苯并
Figure BDA0002809537000000041
嗪基质树脂或这些基质树脂的混合物中，而第二聚合物组分不溶于环氧树脂、氰酸酯或苯并
Figure BDA0002809537000000042
嗪基质树脂或这些基质树脂的混合物中。
在一个实施方案中，第一聚合物组分是聚酰胺和/或非织造物具有环氧化物。特别优选的是，环氧化物以粉末粘结剂的形式存在，该粘结剂散布在非织造物上并已与之热连接。
只要在一些实施方案中以颗粒形式使用粘结剂材料，优选的粒径在50-160微米的范围内，特别优选在80-140微米之间。
对于所有使用非织造物的实施方案来说，如果使用多于一个的非织造层，在每种情况下，可以将不同的非织造物或相同的非织造物用于多轴产品。当使用不同的非织造层时，非织造层可以在其表面重量、其材料和/或其结构方面是不同的。
与以前已知的多轴产品相比，所提出的多轴产品的优点是具有均匀的线型，同时具有较高的纤维体积比例，因为减少了起伏的风险。因此，特别是可以提高多轴产品的抗压强度。此外，与表面重量相当但线层数较少的多轴产品相比，所提出的多轴产品可以更容易地悬垂，也可以通过使用先前预先固定的0°层(例如作为UD带，通过纬线、粉末粘结剂或热塑网固定)。
本发明的另一个主题涉及一种生产多轴产品的方法，如前面所述。
为了生产多轴产品，布置至少三个线层，其中每个线层由复丝增强纱形成，所述复丝增强纱在线层内布置成相互平行且彼此相邻，其中在生产多轴产品时，至少两个线层在0°方向上布置，其中在0°方向上的所有至少两个线层上和/或下面，相对于多轴产品内的0°方向以大于±10°的角度布置至少一个其他线层。
用于生产多轴产品的至少三个线层可以首先在多轴产品的生产过程中形成(在线)，或者可以在生产过程中作为成品层(离线)已经作为用于生产多轴产品的预制产品(例如带)布置。
在0°方向上的至少两个线层在彼此之上布置，而其间没有其他线层(复丝增强纱相对于0°方向以大于±10°的角度布置)。因此，至少一个其他线层可以布置在0°方向上的所述至少两个线层上或下面。如果使用多于一个其他线层，则其他线层位于0°方向上的线层上和/或下面，但决不在其间。当使用多于一个其他线层时，这样生产的多轴产品可以具有关于0°方向上的所述至少两个线层的对称结构。关于0°方向的对称结构例如存在于具有以下结构的多轴产品中：
+45°/0°/0°/-45°
优选地，当生产多轴产品时，至少一个非织造层布置在线层中的一个之间。优选地，非织造层布置在所有线层之间和/或作为最后一层布置在外线层的一侧或两侧。关于用作非织造层的非织造物，应参考已经描述的关于多轴向产品的非织造物的实施方案。
在一个实施方案中，另外可以在多轴向产品的外侧布置金属网。对于金属网的设计，参考已经写过的关于多轴产品的金属网的设计。
在一个优选的实施方案中，在0°方向上布置的至少两个线层中的每一个都在每种情况下由一个布置装置布置。当使用已经预制好的线层时，作为结果，在0°方向上的每个线层使用一个带有卷起的线层的布置装置。
在另一个实施方案中，当提供在线进给时，在生产多轴产品时，在0°方向上的至少两个线层在每种情况下通过一个立线筒子架产生。
在另一个实施方案中，当生产多轴产品时，0°方向上的至少两个线层被布置为所谓的单向织物。在生产过程中，每个单向织物再作为0°方向的线层在生产过程中优选由其自身的布置装置进行铺设。
本发明的另一个主题涉及一种纤维增强复合物，其含有至少一个根据刚才所述的多轴产品。优选的是，该复合物具有复丝维增强纱的多个线层和其间的非织造层。特别优选的是，该复合物具有其他或附加的基质材料，用该材料浸渍线层和非织造层。
因此，本发明的另一个主题还是一种通过附加的基质材料生产复合物的方法。为此，优选地，将最初提到类型的多个多轴产品在彼此之上层叠，并通过加热和压力以及附加的基质材料加以固定，以形成一种组件(复合物)。例如，这种复合物可作为组件用于航空和空间旅行领域或汽车领域。

Claims (18)

1.多轴产品，其包括至少三个线层，其中每个线层由复丝增强纱形成，所述复丝增强纱在线层内布置成相互平行并彼此相邻，其中至少两个线层在多轴产品内布置使得在多轴产品内定义一个0°方向，并且其中至少一个其他线层相对于多轴产品内的0°方向以大于±10°的角度布置，其中基于多轴产品内所述至少三个线层的相对布置，在0°方向上的至少两个线层直接一个接着一个，其间没有其他复丝增强纱层。
2.根据权利要求1所述的多轴产品，其中在0°方向上的至少两个线层在多轴产品中直接相互接触。
3.根据权利要求1或2所述的多轴产品，其中在0°方向上的至少两个线层在每种情况下具有至少150g/m2，优选至少180g/m2的表面重量。
4.根据前述权利要求中任一项所述的多轴产品，其中相对于多轴产品内的0°方向以大于±10°的角度布置的至少一个其他线层在每种情况下具有至少100g/m2，优选至少120g/m2的表面重量。
5.根据前述权利要求中任一项所述的多轴产品，其中复丝增强纱是碳纤维、玻璃纤维或芳纶纱或高延伸UHMW-聚乙烯纱。
6.根据前述权利要求中任一项所述的多轴产品，其中复丝增强纱是根据JIS-R-7608测量的强度为至少5000MPa和根据JIS-R-7608测量的张力模量为至少260GPa的碳纤维纱，和/或根据JIS-R-7608测量的强度为至少4500MPa和根据JIS-R-7608测量的张力模量为至少240GPa的碳纤维纱。
7.根据前述权利要求中任一项所述的多轴产品，其中在所述至少三个线层上、下面和/或之间布置至少一个非织造物和/或在所述至少三个线层上和/或下面布置至少一个金属网。
8.根据权利要求7所述的多轴产品，其中所述至少一个非织造物具有3-25g/m2的表面重量，和/或所述金属网具有60-200g/m2的表面重量。
9.根据权利要求7或8所述的多轴产品，其中所述至少一个非织造物由至少一种第一和一种第二热塑性聚合物组分组成，其中第一和第二聚合物组分具有不同的熔化温度。
10.根据权利要求9所述的多轴产品，其中熔化温度较低的聚合物组分具有80-135℃的熔化温度，和/或熔化温度较高的聚合物组分具有140-250℃的熔化温度。
11.根据权利要求9或10中任一项所述的多轴产品，其中第一聚合物组分是聚酰胺和/或非织造物具有环氧化物。
12.根据权利要求10所述的多轴产品，其中第一聚合物组分可溶于环氧树脂、氰酸酯或苯并
Figure FDA0002809536990000021
嗪基质树脂或这些基质树脂的混合物中，第二聚合物组分不溶于环氧树脂、氰酸酯或苯并
Figure FDA0002809536990000022
嗪基质树脂或这些基质树脂的混合物中。
13.根据前述权利要求中至少一项所述的多轴产品，其中至少一个非织造物具有颗粒状的粘结材料，其中粘结材料的粒径为50-160微米。
14.纤维增强复合物，其中所述复合物具有至少一个根据权利要求1至13中至少一项所述的多轴产品。
15.从至少三个线层生产根据权利要求1所述的多轴产品的方法，其中每个线层由复丝增强纱形成，所述复丝增强纱在线层内布置成相互平行并彼此相邻，其中在生产多轴产品期间，在0°方向上布置至少两个线层，其中在0°方向上的所有至少两个线层的上或下面，相对于多轴产品内的0°方向以大于±10°的角度布置至少一个其他线层。
16.根据权利要求15所述的方法，其中在所述至少三个线层上、下面和/或之间布置至少一个非织造物。
17.根据权利要求14至16中任一项所述的方法，其中在0°方向上布置的至少两个线层中的每一个在每种情况下由一个布置装置布置。
18.根据权利要求14所述的生产复合物的方法，其中使用至少一个根据权利要求1至13中至少一项所述的多轴产品和附加的基质材料。
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CA3102165A1 (en) 2019-12-12
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BR112020024542A2 (pt) 2021-03-02
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