CN1242736A - 具有由玻璃纤维和薄棉纸制成的薄层的复合材料织物 - Google Patents

具有由玻璃纤维和薄棉纸制成的薄层的复合材料织物 Download PDF

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CN1242736A
CN1242736A CN97181175A CN97181175A CN1242736A CN 1242736 A CN1242736 A CN 1242736A CN 97181175 A CN97181175 A CN 97181175A CN 97181175 A CN97181175 A CN 97181175A CN 1242736 A CN1242736 A CN 1242736A
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fabric
roving
layer
roving layer
chopped strand
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CN1089678C (zh
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乔斯·科隆斯·维拉
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Owens Corning Fiberglas Espana SL
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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Inorganic Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)
  • Woven Fabrics (AREA)
  • Paper (AREA)

Abstract

将一个斩碎的玻璃纤维丝束毡片(34)、至少一个长玻璃纤维粗纱层(22,28,30,32)和一个多孔的薄棉纸底层(36)制成一种多层织物(20)。薄棉纸(36)放置在碎丝束毡片(34)的第一侧面上。粗纱层(22,28,30,32)叠置在毡片(34)的一个相对侧面上。这些层被缝编在一起,从而形成了一个当其被用作复合产品中的加强材料时具有有利的树脂浸润性能的复合材料织物。

Description

具有由玻璃纤维和薄棉纸制成的薄层的复合材料织物
总的来说，本发明涉及一种包括斩碎的玻璃纤维丝束毡片在内的复合材料织物。复合材料织物还包括至少一层长长的玻璃纤维粗纱和一个支承碎丝束毡片的薄棉纸底层。将各层缝编在一起，从而构成了复合材料织物。
织物具有各种用途，如它可被用作模塑件或复合制品中的加强组分。例如，可以利用适当的树脂浸润或浸渍本发明的织物，以便生产出杆棒(如路灯杆或远程通信杆)、浴室和卫生间用具、汽车和蓬车车顶、型材、保险杠、引擎罩、叶片(如风车叶片)、滑橇和滑雪板。
在工业领域中，具有玻璃纤维粗纱层的复合材料织物是众所周知的。例如，在造纸业中使用玻璃纤维已有悠久的历史(见授予布莱顿的美国专利US5,318,844)。人们已经将耐高温纤维制成了提供形状稳定性、耐火性和抗弯强度的软纤维或纸张。这些纸张是利用传统的造纸生产设备制成的，其中在均匀薄层中铺放定长短纤维，由此将纤维层压实成一张纸或纤维制品。
这些多层复合材料织物通常由一个碎丝束毡片支承，所述碎丝束毡片包括一层随意铺放的玻璃纤维丝束。许多已知的碎丝束毡片制造工艺都需要采用粘结剂、黏附材料、胶或其它含有水分的浆糊，以便连接纤维并形成碎丝束毡片。这些工艺要求有一个干燥或固化粘结剂、黏附材料、胶或浆糊的步骤。因此，这样的工艺涉及在生产复合材料织物时使用附加材料并需要额外的时间。
人们已经知道了许多种复合材料织物。授予怀特利等人的美国专利US4,499,134披露了一种包括一层纸和一层耐磨的高温稀松非织织物在内的复合物，其中纸的厚度约为0.01英寸～0.05英寸(约等于0.254mm～1.27mm)，并且它具有51b/ft3～151b/ft3(80.092kg/m3～240.277kg/m3)的体积密度，所述稀松非织织物可以是由象玻璃纤维这样的纤维构成的，这些纤维被放置在纸的至少一个表面上。授予比欧的美国专利US4,983,453记载了一种复合的拉挤制品，它是由玻璃纤维粗纱丝束和纤维素毡片制成的，而纤维素毡片的基重通常约为100g/m2～800g/m2。
尽管已经知道了许多种复合纤维材料，但是仍然需要一种当其被用于制造增强复合材料产品时具有更好的树脂浸渍或浸润性能的复合材料织物。另外，还需要一种成本相对低的具有良好浸润和浸渍性能的织物。
此外，人们需要一种改进的复合材料织物，它不需要在制造支承许多层复合材料织物的碎丝束毡片时使用粘结剂、黏附材料或浆糊。还需要一种制造这样的多层复合材料织物的方法，它在制造复合材料织物的碎丝束毡片的过程中不需要干燥或固化的步骤。
因此，本发明的一个目的是力求获得一种可低成本制造的复合材料织物，它具有提高的浸润性能。本发明的另一个目的是提供一种制造多层复合材料织物的方法，其中在不需要干燥或固化的情况下制成毡片。
这样的目的是通过本发明的复合材料织物实现的，它包括一个斩碎的玻璃纤维或丝束毡片、一个薄棉纸底层和至少一层玻璃纤维粗纱，这些粗纱最好是由长纤维制成的。斩碎的玻璃纤维丝束毡片具有两个侧面并包括随意铺放并定向的玻璃纤维丝束。薄棉纸底层被放置在碎丝束毡片的第一侧面上，由此支承着碎丝束毡片。碎丝束毡片最好基本上不含黏附材料、粘结剂、浆糊或胶。各粗纱层最好包括许多根玻璃纤维粗纱，它们是沿复合材料织物的轴向单向铺放的。玻璃纤维粗纱层叠放在碎丝束毡片的另一个侧面上。复合材料织物的各层即薄棉纸底层、碎丝束毡片、玻璃纤维粗纱层被缝编在一起，从而构成了复合材料织物。
本发明的多层复合材料织物制造方法的一个优选实施例包括提供一个薄棉纸底层并随意铺放和定向地将斩碎的玻璃纤维丝束放置在薄棉纸层上，由此在薄棉纸底层的一个侧面上形成了一个碎丝束毡片。随后，将长玻璃纤维粗纱铺放在碎丝束毡片上，由此形成了一个粗纱层。接着，将薄棉纸底层、碎丝束毡片和玻璃纤维粗纱层缝编在一起，从而形成了复合材料织物。
本发明织物的一个优点是当其在制造复合产品时被用作加强材料时具有更好的被聚合树脂浸润和浸渍的性能。树脂更易于浸润和浸渍复合材料织物是因为薄棉纸层整体提高了织物的吸收性。另外，由于缝缀而在织物中形成的针刺孔以及在毡片中的碎玻璃纤维之间的孔隙有助于提高树脂浸渍。另外，通过采用低成本的基底材料而获得了成本的降低。与之相比，用作玻璃纤维毡片或复合材料织物的底层的已知材料不仅昂贵，而且没有提高浸润性能。
根据以下结合附图的具体描述，本发明的这些和其它的优点、目的和特征将变得清楚。
图1是本发明的多层复合材料织物的平面图。
图2是沿线2-2的图1所示复合材料织物的横截面图。
图3是图1的复合材料织物的局部分解透视图。
本发明的复合材料织物包括被缝缀在一起而形成了一个整体产品的各层。这些层包括斩碎的玻璃纤维毡片、至少一层长玻璃纤维粗纱以及一薄棉纸底层。复合材料织物具有多种用途，但它尤其是可被用于制造由热塑性或热固性树脂制成的复合产品，其中织物以本领域中公知的方式形成了塑料产品的支承层、加强材料或底基。
参见附图，在这几张图中，相同数字表示相同部件，其中大体上示出了本发明的复合材料织物20的一个优选实施例。复合材料织物20包括许多层，它包括玻璃纤维粗纱上层22、玻璃纤维粗纱层28、30、32。复合材料织物20还包括一个斩碎的玻璃纤维丝束毡片层34和一个薄棉纸底层36。复合材料织物20的各层被缝纫线26缝缀在一起，这在图1中以优选的锯齿交错方式示出。上层22包括许多根单向布置的玻璃纤维粗纱24。各根粗纱24包括许多根被聚在一起而形成了大致平行的无扭结构的玻璃纤维长丝23。
碎丝束毡片34包括一层随意铺放并定向的玻璃纤维丝束35，在图2和图3中示意地示出了这些纤维丝束。如以下所述的那样，可以采用传统的干叠合铺设丝束35。玻璃纤维丝束35在一起构成双罗纹组织而形成了毡片34。碎丝束毡片34优选地基本上不含粘结剂、黏附材料、浆糊或胶。毡片34的重量轻，但它仍支承着玻璃纤维粗纱层22、28、30、32。毡片34的厚度最好约为0.50mm～3.00mm且更好地约为1mm～2mm，它的体积密度约为0.040lb./in3～0.080b./in3(1.11g/cm3～2.21g/cm3)。碎丝束毡片34具有对置的侧面38、40，如以下所述的那样，附加层都放置在上述侧面上。
构成碎丝束毡片34的玻璃纤维丝束35或玻璃纤维长丝包括本领域公知的适当类型的玻璃纤维，如被切成不同长度的粗纱或被切成不同长度的废麻纱(单纱多兼容直纱)。从欧文斯科尔宁和几个其它货源处可获得可用于本发明的典型斩碎的丝束毡片。纤维35可以是定长短纤维，也可以是长纤维。例如，一种制造碎丝束毡片34的方法包括按照连续长丝的形式挤出玻璃纤维并使长丝内交联捻合在一起。与此相似的，可以由随意铺放并定向的定长短纤维制成毡片34。
将一个薄棉纸底层36放置在碎丝束毡片34的下侧面40上。底层36尤其是在下述的复合材料织物20的制造工艺中支承着玻璃纤维丝束35和毡片34。薄棉纸底层36包括标准的薄棉纸产品，它的体积重量约为20g/m2～60g/m2且最好约是20g/m2～35g/m2。薄棉纸底层的最佳体积重量为25g/m2。优先选用比较多孔的且可以通过传统工艺由木材、植物或破布纤维制成的传统的或标准的薄棉纸来制造底层36。适用的薄棉纸可以从埃尔比纸张有限责任公司(意大利，Cuneo)和其它供货商处购得。在制造本发明的复合材料织物时使用了薄棉纸底层，但它无需赋予所用织物结构整体性。因此，例如，在高温应用场合中可以不损及织物性能地部分或完全破坏这一层。薄棉纸底层36优选地支承碎丝束毡片34，从而可以不用粘结剂、黏附材料、浆糊或胶地制成毡片34。
玻璃纤维粗纱层22包括许多粗纱24。每根粗纱24包括许多根玻璃纤维23，它们聚集在一起而形成了几乎平行的且通常无扭转的结构。沿复合材料织物20的纵向轴线单向地调整粗纱24的走向。于是，每根粗纱24一般相互平行。因而，玻璃纤维粗纱层22提高了沿复合材料织物20的纵向轴线的强度。玻璃纤维丝束23可以是定长短纤维形式的，或者是长纤维形式的。在制造玻璃纤维粗纱层22时，可以按照连续长丝的形式挤出玻璃纤维23。玻璃纤维可以按照传统方式与许多根其它玻璃纤维相结合。玻璃纤维丝束优选地集束成玻璃纤维粗纱24。或者，可以通过传统的湿叠合或干叠合方法将长度一致的定长短纤维制成玻璃纤维粗纱层。
玻璃纤维粗纱层28与粗纱层22相似。但是，粗纱层28中的粗纱42是按照相对复合材料织物20的纵轴约成+45°角地以单向方式布置的。许多根玻璃纤维丝束23按照大致平行且无扭转的布局集结在一起，由此形成了粗纱层28的粗纱42。玻璃纤维粗纱42沿粗纱42的方向即沿一个相对复合材料织物20的纵轴大约成+45°的轴向给复合材料织物20提供了强度。
在玻璃纤维粗纱层30中，粗纱44是按照相对复合材料织物20的纵轴约成-45°地以单向方式布置的。于是，粗纱层30中的粗纱44基本上垂直于粗纱层28中的粗纱42。玻璃纤维粗纱层30沿粗纱44的方向即沿一个相对复合材料织物20的纵轴大约成-45°的轴向给复合材料织物20提供了强度。
玻璃纤维粗纱层32包括许多根粗纱46，它们基本上垂直于复合材料织物20的纵轴地按单向方式布置。每根粗纱46包括许多玻璃纤维丝束23，这些丝束按照大致平行且无扭转的布局集结在一起。玻璃纤维粗纱层32沿一个垂直于复合材料织物20的纵轴的轴向给复合材料织物20提供了强度。
优选的，每个玻璃纤维粗纱层22、28、30、32的厚度约为0.50mm～3.00mm且最好约为1mm～2mm。粗纱层22、28、30、32叠置在碎丝束毡片34的对置侧面38上。确切地说，粗纱层32的下侧面48靠在碎丝束毡片34的上侧面38上。粗纱层30叠置在粗纱层32的上侧面50上。粗纱层28叠置在粗纱层30上，粗纱层22叠置在粗纱层28上。可以按照适用于预想设计的理想顺序布置各玻璃纤维粗纱层。另外，复合材料织物20可以包括多于或少于所示四层的粗纱层22、28、30、32。为了给复合材料织物20提供附加强度和整体性，一般在复合材料织物20中包括至少一个粗纱层。
复合材料织物20的各层(在所示实施例中是上玻璃纤维粗纱层22、玻璃纤维粗纱层28、30、32、碎丝束毡片34和薄棉纸底层36)通过缝缀被连接在一起，从而形成了一个整体的产品。缝纫线26按照任何适当的缝制或缝缀图案从复合材料织物20的上表面起穿过各层地到达织物20的下表面。缝纫线26可以由与粗纱中的长丝即玻璃纤维相同的材料构成。但是，缝纫线26最好是由聚合材料如聚酰胺、聚酯或聚丙烯材料制成的。适当的缝纫线可以通过各种渠道如从La Seda de Barcelona(西班牙，巴赛罗纳)购得。在一个优选的实施例中，缝纫线26形成了锯齿交错的图案。在这样的锯齿交错图案中，缝纫线26以交替斜对角的方式横穿过在粗纱层22的上表面25上的粗纱24。缝纫线26在粗纱层22的各玻璃纤维粗纱24之间穿过复合材料织物20。复合材料织物20是自承重的轻型产品，它在玻璃纤维粗纱层22、28、30、32的方向上具有提高了的强度。
在一个优选方法中，包括各层在内的复合材料织物20是这样制成的。优选地，先将一层薄棉纸36铺放在一个支承面(未示出)上。接着，此方法包括接连地将一层基本上均匀的斩碎的玻璃纤维丝束35放置在薄棉纸层36上，由此在薄棉纸底层36的侧面上形成了一个碎丝束毡片34。按照随意铺放并定向的方式铺放斩碎的纤维丝束35。薄棉纸底层36形成了玻璃纤维丝束35的支承或基底，由此在制备碎丝束毡片34时无需使用粘结剂、浆糊或胶。接着，将许多玻璃纤维粗纱46铺放在毡片34上，由此在其上形成了第一玻璃纤维粗纱层32。基本上垂直于复合材料织物纵轴地按照单向方式铺设粗纱46。每根粗纱46包括许多根长丝或纤维23，这些长丝或纤维聚集成大致平行的无扭转结构。接着，可例如沿另一个如垂直于复合材料织物纵轴的轴向按照单向形式以与第一层基本上相同的方式将另外一个玻璃纤维粗纱层30铺放在第一层粗纱32上。沿所希望的不同轴向并按照相似的方式将其它的玻璃纤维粗纱层22、28先后铺放在先前的粗纱层上。接着，按照适当的方式用缝纫线将各层缝缀在一起，从而形成了复合材料织物。
现在，已经描述完了本发明的优选实施例和形态。那些本领域的普通技术人员将认识到，可以在不超出本发明精神的情况下对本发明作出各种改动。因此，我们不希望用上述的具体描述来限定本发明，而是想用后续的权利要求书和其它等同替换来限定本发明。

Claims (20)

1.一种织物，它包括：
(a)许多层，其中包括：
一个具有第一侧面和与第一侧面相对的第二侧面的碎丝束毡片，碎丝束毡片包括一层随意铺放的斩碎的玻璃纤维丝束；第一玻璃纤维粗纱层，它叠置在所述碎丝束毡片的第一侧面上；一个多孔的薄棉纸底层，它的体积重量约为20g/m2～60g/m2且它放置在所述碎丝束毡片的第二侧面上以便支承所述碎丝束毡片；以及
(b)将所述的许多层连接在一起的缝纫线。
2.如权利要求1所述的织物，其特征在于，碎丝束毡片主要是由所述斩碎的玻璃纤维丝束构成的。
3.如权利要求1所述的织物，其特征在于，所述薄棉纸底层的体积重量约为25g/m2。
4.如权利要求1所述的织物，其特征在于，所述第一粗纱层包括一层沿织物的第一轴向布置的单向长玻璃纤维粗纱。
5.如权利要求4所述的织物，其特征在于，所述第一轴向是纵轴向；所述的许多层还包括叠置在第一粗纱层上的且包括沿与第一轴向不同的织物的第二轴向平行单向布置的长玻璃纤维粗纱的第二粗纱层。
6.如权利要求1所述的织物，其特征在于，所述碎丝束毡片包括一层基本上均匀的且随意铺放且定向的斩碎的玻璃纤维丝束。
7.如权利要求7所述的织物，其特征在于，所述碎丝束毡片包括一层随意铺放且定向的玻璃纤维丝束，且所述薄棉纸底层的体积重量约为25g/m2。
8.如权利要求1所述的织物，其特征在于，所述缝纫线是按照锯齿交错图案缝纫上去的，且所述缝纫线是由聚合材料制成的。
9.如权利要求1所述的织物，其特征在于，沿织物的纵轴向布置所述第一粗纱层，并且所述的许多层还包括：
叠置在第一粗纱层上且按照相对纵轴向约成-45°角地布置的玻璃纤维粗纱的第二粗纱层；
叠置在第二粗纱层上且按照相对纵轴向约成+45°角地布置的玻璃纤维粗纱的第三粗纱层；
叠置在第三粗纱层上且垂直于纵轴向地布置的玻璃纤维粗纱的第四粗纱层。
10.一种复合产品，它包括：
(a)一个加强织物制品，它包括：
(i)许多层，其中包括：
一个具有第一侧面和与第一侧面相对的第二侧面的碎丝束毡片，碎丝束毡片包括一层随意铺放的斩碎的玻璃纤维丝束；第一玻璃纤维粗纱层，它叠置在所述碎丝束毡片的第一侧面上；一个多孔的薄棉纸底层，它的体积重量约为20g/m2～60g/m2且它放置在所述碎丝束毡片的第二侧面上以便支承该碎丝束毡片；
(ii)将所述许多层连接在一起的缝纫线；以及
(b)一种浸渍所述加强织物的聚合树脂。
11.如权利要求10所述的复合产品，其特征在于，所述该薄棉纸底层的体积重量约为25g/m2。
12.如权利要求10所述的复合产品，其特征在于，第一粗纱层包括一层沿织物的第一轴向布置的单向长玻璃纤维粗纱。
13.如权利要求12所述的复合产品，其特征在于，第一轴向是纵轴向，所述的许多层还包括叠置在第一粗纱层上且包括沿与第一轴向不同的织物的第二轴向平行单向地布置的长玻璃纤维粗纱的第二粗纱层。
14.如权利要求10所述的复合产品，其特征在于，所述碎丝束毡片主要包括一层随意铺放且定向的玻璃纤维丝束，所述薄棉纸底层的体积重量约为25g/m2。
15.如权利要求10所述的复合产品，其特征在于，沿织物的纵轴向布置第一粗纱层，并且所述的许多层还包括：
叠置在第一粗纱层上且按照相对纵轴向约成-45°角地布置的玻璃纤维粗纱的第二粗纱层；
叠置在第二粗纱层上且按照相对纵轴向约成+45°角地布置的玻璃纤维粗纱的第三粗纱层；
叠置在第三粗纱层上且垂直于纵轴向地布置的玻璃纤维粗纱的第四粗纱层。
16.一种制造织物的方法，它包括以下步骤：
(a)通过以下步骤形成许多层：
(i)按照随意铺放且定向的方式将斩碎的玻璃纤维铺放在一个多孔的薄棉纸底层的一个侧面上而形成了一个碎丝束毡片，所述薄棉纸底层的体积重量约为20g/m2～60g/m2；
(ii)将玻璃纤维粗纱铺放在所述碎丝束毡片上，从而形成了第一粗纱层；
(b)将所述许多层用线缝缀在一起从而形成了织物。
17.如权利要求16所述的方法，其特征在于，如此铺放斩碎的玻璃纤维，即所述碎丝束毡片具有一个基本上均匀的厚度。
18.如权利要求16所述的方法，其特征在于，所述玻璃纤维粗纱是连续的且它们是沿织物的第一轴向被单向铺放在所述碎丝束毡片上的。
19.如权利要求16所述的方法，其特征在于，所述成型步骤还包括(iii)沿不同于第一轴向的第二轴向将由长玻璃纤维粗纱组成的第二粗纱层单向地铺放在所述第一粗纱层上。
20.如权利要求16所述的方法，其特征在于，不使用任何粘结剂、黏附材料、浆糊或胶地进行铺放斩碎的玻璃纤维以形成碎丝束毡片的步骤。
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