DE4024510A1 - DEEP-DRAWABLE TEXTILE MATERIAL AND MOLDED BODIES MADE THEREOF - Google Patents

Abstract

There is described an isotropic, readily deep-drawable nonwoven which has been formed as a filament nonwoven and consists of low-orientation, coarse-denier filaments to an extent of not less than 30% by weight and which has been consolidated mechanically only. Furthermore, a resinated, sheetlike prepreg produced from the nonwoven; a three-dimensional shaped textile structure produced using the resinated or unresinated deep-drawable nonwoven; and a sandwich material with a core comprising said three-dimensionally shaped, resinated textile structure. There are also described processes for manufacturing the abovementioned objects. <IMAGE>

Description

The present invention relates to a thermoformable nonwoven, one of them made resinous sheet prepreg, one using the non-resinous or resinous thermoformable nonwoven fabric three-dimensionally deformed textile structure and a sandwich material with one Core from said three-dimensionally deformed, resin-coated textile structure. The invention further relates to methods for producing the above designated items.

EP-A-2 47 232 describes nonwovens made from filaments low pre-orientation, which results in an elongation at break of over 100% or birefringence from 0.01 to 0.07. These nonwovens are thermally pre-consolidated, moistened and heated by hot embossing rollers then thermally fixed under tension. This results in solidified Embossing points that strongly indicate the mobility of the filaments in the nonwoven limit, and results from the subsequent fixation under tension an anisotropy of the thermomechanical properties, which ver Formability of such nonwovens strongly at least in the direction of tension impaired.

DE-A-30 29 752 discloses a method for producing a deep-drawn molded part made from a staple fiber fleece Staple fiber fleece is used, which is at least 10% by weight stretchable Fibers with an elongation at break at 150 ° C below the melting point of contains at least 100%, which is solidified by needles and that at one Temperature between 150 ° C and the melting point of the stretchable Fibers is deep drawn.

The fleece can be a thermoplastic or thermosetting binder be additionally reinforced. The staple fibers used for this material can consist of various synthetic polymers and have, according to the examples, stack lengths of approx. 50-80 mm and  Single filament titer from 1.5 to 20 den.

The molded parts are suitable as self-supporting filters. you are however, because of the exclusive use of staple fibers mechanically less resilient. The document gives no indication that a deep-drawable nonwoven could also be constructed from continuous fibers; rather, the person skilled in the art is led to assume that the Thermoformability of this known fleece from the use of Short cut fibers result which are relatively easy to get together in the deep drawing process can slide past.

A deformable spunbonded web made exclusively from partially stretched Endless synthetic fibers is known from DE-B 15 60 797. The The fibrous material of these nonwovens can be made of polyamides, polyesters or Polyolefins exist. This fleece becomes pattern-like for consolidation compressed and impregnated with locally varying binder concentrations. This particular type of consolidation is according to the information given in this Print for the deformability of the fleece of crucial Importance. Similar to that described in EP-A-2 47 232 punctiform solidification, however, also results in anisotropy in the mobility of the filaments within the nonwoven, which the three-dimensional deformability of the nonwoven is impaired.

It is also known from EP-A-2 50 005, from fabrics and normal fleeces deformed three-dimensional structures to manufacture. The gain in area occurring in the deep-drawing process is said to increase the information in this document only from the constructional extension of this Flat structures result and are accordingly small.

The present invention makes an isotropic, well thermoformable Nonwoven fabric provided which is among the normal Processing conditions, especially in the impregnation process, a very shows good dimensional consistency, and at the same time one for all practical Use cases with a sufficiently large deep-drawing ratio.

The isotropic, deep-drawing nonwoven according to the invention is as Filament nonwoven formed and characterized in that it too  at least 30% by weight from low-orientation, coarse-titer filaments a titer of more than 7 dtex and that it solidifies mechanically is.

Mechanical strengthening can be carried out in any manner known per se take place, e.g. B. by needles or by hydrodynamic means Fluid jets, as described for example in EP-A-01 08 621 has been.

The orientation of those contained in the nonwovens according to the invention low-oriented, coarse-titer filaments, is expediently so set to have a maximum tensile elongation of at least 80%, preferably corresponds to at least 100%. An upper limit for the The maximum tensile strength expansion of the low-orientation, coarse-titer filaments is in Basically given only by their manufacturability. However, it is advantageous adjust the orientation of these filaments so that a Maximum tensile elongation between 100 and about 350% results. Especially it is preferred to determine the degree of orientation of the slightly oriented, coarse titers Filaments, d. H. their maximum tensile strength extension to the intended Intended purpose, d. H. the three-dimensional one to be achieved by deep drawing Adjust the deformation that in the stretched areas coarse titre filaments cannot tear, but not too large either Have more stretchability. It is therefore particularly preferred that Orientation of the coarse titer filaments, d. H. their maximum tensile strength stretch like this adjust that after the deep-drawing deformation of the invention Fleece the coarse-titer filaments in the stretched areas one more Residual stretchability of about 10 to 50%, in particular 10 to 30%, exhibit.

The coarse-titer filaments contained in the nonwovens according to the invention, usually have individual titers of 7 to 30 dtex, preferably 10 up to 25 dtex. Titers outside of this are also expediently to be observed Titer limits are possible if care is taken that the above is closer described conditions for the orientation of the filament material  can be met.

The deep-drawable materials according to the invention exist for special fields of application Nonwovens made from 100% of the slightly oriented, coarse titer filaments. However, it has been shown that it is surprisingly possible, too to produce nonwovens which are easy to deep-draw according to the invention and which are up to 70% contain other fibers.

These "other fibers" can be any known for nonwoven manufacture appropriate fiber type. They preferably have a normal one to high degree of orientation and can therefore be normal to high be tearproof and they can be as staple fibers or, preferably, as Continuous fibers are present. Therefore, in the following description, the term "Other fibers" always include all of these types of fibers.

It is surprising that such, only about 30% poorly oriented, Nonwovens according to the invention having coarse titre filaments are still good allow to deep-draw, while known nonwovens only a moderate deep-drawing ability have, and at higher thermoforming ratios in the stretched zones tear. The deep-drawing ability of nonwovens according to the invention with a The majority of other fibers may be due to the fact that the portions of low-orientation, coarse-titer filaments contained in the fleece perform a surprisingly good support and stabilization function that tearing of the remaining fiber parts of the fleece according to the invention prevent surprisingly effectively. Preferred nonwovens according to the invention contain a proportion of 40 to 85 wt .-% of the low-oriented, coarse titre filaments or, as already explained above, they consist of 100% from slightly oriented, coarse titer filaments.

Neither the poorly oriented, coarse titer filaments, nor the others Fibers of the nonwoven according to the invention all have the same titer to have. Rather, two or more groups can also be small oriented, coarse titre filaments with different, above 7 dtex lying titers may be contained in the same nonwoven or the titers of the Slightly oriented, coarse titer filaments can be found in an area above  7 dtex be statically distributed, as long as their orientation is only Maximum tensile strength expansion of at least 80%. The same naturally also applies to the other fibers of the nonwoven fabric according to the invention. These can also be in one and the same Nonwoven fabric in various titers or in a spectrum of titers in which the Titers are statistically distributed, but the ones in them are Titer limitation to values above 7 dtex does not apply.

The titers of these "other fibers" can therefore also be smaller than 7 dtx and are usually 1 to 30 dtex.

By choosing the titer mixture of the filaments and fibers, the Character of the nonwovens according to the invention within very wide limits can be varied. A higher proportion of coarse titer filaments and fibers for example, to increased rigidity and less area coverage; a a higher proportion of fine titers below 10 dtex is particularly preferred if the area coverage of the nonwoven fabric according to the invention should be evened out and / or denser.

There are several ways to distribute the poorly orientated, coarse titre and the other fibers in the invention thermoformable nonwovens. The slightly oriented, coarse titre, filaments and the other fibers can be used in the thermoformable nonwovens are practically homogeneous mixture, d. that is, on average in each Space element of the fleece the distribution of poorly oriented, coarse titers and other fibers is approximately the same. The thermoformable according to the invention However, nonwoven fabric can also have a layer structure in which the low oriented, coarse titre filaments and the other fibers in different layers are included. Layers change with this poorly oriented, coarse titre filaments and layers with others Fibers from each other. It is preferred that at least one Outside of the layered nonwoven, in particular both Outside layers of low-orientation, coarse-titer filaments consist. The layers of such a nonwoven fabric according to the invention are also conveniently mechanically, for. B. by needles, connected with each other.  

The excellent supportability of the thermoformable materials according to the invention Nonwovens can also be used in such a way that a the nonwoven according to the invention combined with other known nonwovens and is connected selectively or over the entire surface. This also creates one Layer structure due to the presence of at least one layer of a nonwoven fabric according to the invention has good thermoformability. When combining a laminate according to the invention with others In principle, the number of layers is not known for known laminates limited, but is determined by the intended use. Such a combination usually alternates according to the invention and conventional nonwovens and can be used as an outer layer on one or both sides have a nonwoven according to the invention or a customary nonwoven.

The basis weight of the nonwovens according to the invention is also essential, determined by the intended use of the material and is usually in the range from 50 to 500 g / m², preferably from 100 up to 300 g / m².

The excellent deformability of the nonwoven fabric according to the invention is based not only on the good ductility of the contained therein, low oriented, coarse titre filaments, but also on the good Mobility of the filaments in the purely mechanically bonded nonwoven. Also the higher volume of mechanically bonded nonwovens compared to thermally bonded is advantageous for many applications.

The coarse-titled individual filament contained in the nonwoven fabric according to the invention elements result in good inherent stability of the deep-drawn molded articles themselves if they contain no or no stabilizing resin.

The thermoformable spunbonded fabric according to the invention is produced in a manner known per se by placing the dilaments on a moving Sieve pad to a tangled fleece and is characterized in that at least 30% by weight of low-orientation, coarse-titer filaments with a titer  of more than 7 dtex. The blowing nozzles for the filament withdrawal are set so that these coarse titer filaments are relatively receive little pre-orientation, that a maximum tensile strength extension of corresponds to at least 80%, preferably at least 100%. Especially It is advantageous to adjust the trigger nozzles so that depending on the planned use of the thermoformable according to the invention Fleece the slightly oriented, coarse titer filaments Have maximum tensile strength strains in the range of 100 to 350%. Preferably, the single titer of the coarse titled is slightly oriented Filaments in the range between 8 and 30 dtex and their share of Total weight of the fleece chosen between 80 and 100 wt .-%. The Amount of filaments deposited per m² is according to the above Criteria are measured, usually 50 to 500 g, preferably 100 up to 300 g filaments per m².

Filament is preferably deposited using a rotating one Baffle plate and in particular with a downstream guide surface like this is described for example in German Patent Specification 27 13 241. To Production of the thermoformable spunbonded nonwovens according to the invention preferred layer structure, with the slightly oriented, coarse titer Filaments and other fibers are contained in different layers, the filament is deposited by several in the direction of movement Sieve pad from rows of storage organs one behind the other which are alternately poorly oriented, coarse titre, filaments and others Fibers are placed. The consolidation of the freshly filed Spunbonded fabric is made in a manner known per se by mechanical means, for example by needles or by hydrodynamic consolidation by means of fluid jets as described, for example, in EP-A-01 × 08 621 is described.

The filaments and fibers of the thermoformable material according to the invention In principle, spunbonded nonwovens can be made from all spinnable polymer materials consist. The polymer material from which the poorly oriented, coarse-titled Filaments are manufactured, however, the manufacture of filaments  allow the maximum tensile strength extension of at least 80, preferably 100 in particular have 100 to 350%. For the others, in the nonwovens according to the invention optionally contain fibers no such restrictions.

Preferred polymer raw materials for the production of the invention thermoformable nonwovens are polyesters, polyamides and polyacrylonitrile. Polyesters and particularly those which are particularly preferred at least 80% built up from terephthalic acid and ethylene glycol units are. In particular, a polymer raw material made of pure or containing at most 5% modifying assembly Polyethylene terephthalate.

Polyester building blocks, which in addition to terephthalic acid and ethylene glycol in the Polyesters to be used can be included, which are usually in spinnable polyesters used such. B. isophthalic acid, Sulfoisophthalic acid, naphthalene carboxylic acids, aromatic Hydroxycarboxylic acids, for example p-hydroxybenzoic acid, aliphatic Dicarboxylic acids with about 4 to 10 carbon atoms, for example adipic acid, Glycols with 3 to 10 carbon atoms, diglycol, triglycol or polyglycol.

The present invention also relates to a thermoformable nonwoven of the type described above, additionally with a thermoplastic or thermosetting resin is impregnated. As a thermoplastic or thermosetting resin is preferably used that the Nonwoven stiffened so that it becomes self-supporting. A is particularly preferred Nonwoven fabric according to the invention, which with a known, heat-curing Resin, in particular a phenol or melamine resin is impregnated. The Resin pad, d. i.e. the amount of resin applied per m² of textile material, depends on the area of application and is preferably dimensioned so that there is an essentially open-pore nonwoven network.

A material must be provided under an open-pore nonwoven network essentially the open-pore structure of the original fleece has retained, in which the resin thus only the individual filaments completely or  partially covered and binding points at the filament crossing points trains.

Suitable application quantities of the resin are in the range from 20 to 80, preferably from 40 to 50% by weight of the semi-finished product. Within the the specified ranges, the amount of resin can be appropriately added to the m² Adjusted weight of the nonwoven fabric according to the invention. When in use a heavy nonwoven according to the invention is preferably carried out in the upper half of the specified range, for light textiles in the lower half. For special applications it can also be advantageous the amount of resin to increase so much that even in the stretched state a resin film remains between the threads of the nonwoven network.

The preparation of the resin-impregnated invention described thermoformable nonwovens can be easily made by the a nonwoven fabric described above using a conventional resin impregnation process submits. The resin can be applied in the usual way by brushing, brushing, Squeegee, splash or by diving. The one with resin nonwoven fabric is then expediently by squeezed a pair of squeeze rollers onto the desired resin holder. In a preferred embodiment, the resin is applied by a "Reverse process" in which the resin is first applied to a substrate is applied evenly. Then with the resin-coated carrier brought deep-drawable nonwoven according to the invention into close surface contact, the nonwoven fabric by its capillary forces the resin from the carrier sucks.

It is by no means necessary that the resin application over the entire The area of the nonwoven must be uniform. Rather, the resin also in the form of a regular pattern or in an irregular but statistically uniform distribution can be applied. Here is, however Please note that the unpainted areas do not become too large, so still sufficient stiffening of the entire undeformed or three-dimensional deformed fabric is achieved.

An effective statistical resin distribution results, for example when the resin is applied to a by the reverse process described above  Nonwoven fabric according to the invention is applied, which has a layer structure shows, on the one side predominantly coarse, poorly oriented, on the other side predominantly fine titled, normal or strongly oriented Filaments are present. The resin transfer takes place from the coarse titre side and the coarse titre filaments pull the predominant part of the resin itself and form after deep drawing and hardening of the resin a particularly effective stiffened Support network.

Thermoplastic resins are used for the impregnation process expediently in the form of solutions or preferably of Emulsions applied; thermosetting resins expediently in the commercial form as highly concentrated aqueous solutions or Dispersions.

The inventive, optionally resin-impregnated, thermoformable Nonwoven fabric can be particularly advantageous for three-dimensional manufacture deformed textile fabrics can be used. This too three-dimensional structures are the subject of the present invention. They consist of a three-dimensionally shaped, open-pore nonwoven, which is characterized in that at least 30 wt .-% of the filaments low-oriented, coarse-titer filaments that are also in the deformed Areas only stretched to below their maximum tensile strength stretch, d. H. Not are torn.

They contain a relatively coarse-pored support network that is small oriented, coarse-titled filaments in the field of deformation are stronger, is formed and if necessary additionally is stiffened by a thermoplastic or thermosetting resin. In the three-dimensionally deformed textiles according to the invention Fabrics that are not exclusively made up of the coarse-titer filaments exist, extends between the relatively coarse Open the support network from the other, possibly fine-tuned Filaments formed, possibly also resin-reinforced porous fleece with its countless  fine openings.

In a special, but less because of the higher weight preferred embodiment, the pores of the deformed nonwoven fabric also be filled with the thermosetting or thermoplastic resin.

Fig. 1 shows schematically a possible shape for a three-dimensionally deformed sheet ( 3 ) according to the invention with a plurality of "cups" ( 5 ) pulled out of a textile base ( 4 ) (nonwoven fabric).

FIG. 2 shows schematically an enlarged representation of one of the “wells” ( 5 ) of the structure of FIG. 1.

In Figs. 1 and 2 of clarity and is schematically only formed from the low-orientated, coarse denier filaments support network and only the structure of the side facing the viewer faces of the "wells" shown for reasons, but not through the open-pored non-woven Structure visible through the back. The Fig. 2 schematically shows particularly clearly the open fiber interstices of the open-pored non-woven fabric structure.

In particular with a view to further use as a core material Specified embodiment for the production of laminates the three-dimensionally deformed sheet-like Textile material on a base surface in a regular arrangement a variety of results. In a further embodiment, this three-dimensionally deformed material according to the invention at the level of Base area in a regular arrangement a variety of surveys and Deepening. The elevations and depressions can take the form of Cups with a round or square base or z. B. from webs, which expediently a flat plateau or a flat bottom have, preferably all in one plane and parallel to the base surface lie.  

The three-dimensionally deformed sheet-like Textile material is made either by using a resinated nonwoven according to the invention a known Subjecting thermoforming process, or by making an uncured the nonwoven fabric according to the invention deep-draws and the three-dimensional obtained deformed structure then resinated, or by having an uncured matching nonwoven fabric according to the invention together with a resin film Subject weight to the deep drawing process.

Another object of the present invention is a sheet Sandwich body consisting of two outer solid cover layers that over a core consisting of the one described above three-dimensionally deformed, resin-reinforced sheet-like textile material are connected. The connection between Cover layers and the plateau surfaces of the elevations or Bottom surfaces of the depressions of the core material according to the invention can by conventional lamination processes using adhesives, especially of cold or heat curing adhesives such. B. Epoxy resins or thermosets are made. Because of the big Contact area between the core material and the outer layers proves the bond is extremely stable. Despite the open pore The nonwoven structure of the core material according to the invention thus have sandwich moldings produced a surprisingly high compressive strength at extremely low weight. They are therefore ideal as Material for the interior of vehicle, in particular airframes. Here are three-dimensional deformed textile nonwovens according to the invention made of flame retardant filament material is particularly preferred.

FIG. 3 shows a sandwich structure (6) with the top surfaces (7) and (8) and a core (9) of an inventive, three-dimensionally deformed sheet.

Claims (22)

1. Isotropic, good thermoformable nonwoven fabric, characterized in that it is designed as a filament nonwoven fabric which contains at least 30% by weight of slightly oriented, coarse-titered filaments with a titer of more than 7 dtex and is only mechanically consolidated. 2. Nonwoven fabric according to claim 1, characterized in that the Orientation of the slightly oriented, coarse titer filaments of one Maximum tensile elongation of at least 80%, preferably of corresponds to at least 100%. 3. Nonwoven fabric according to at least one of claims 1 and 2, characterized characterized that the slightly oriented, coarse titre filaments Have individual titers of 7 to 30 dtex. 4. Nonwoven fabric according to at least one of claims 1 to 3, characterized characterized in that the nonwoven to 40 to 85 wt .-% from the low oriented, coarse-titer filaments. 5. Nonwoven fabric according to at least one of claims 1 to 4, characterized characterized that it is exclusively from geirng oriented, coarse titre filaments of poor orientation. 6. Nonwoven fabric according to at least one of claims 1 to 5, characterized characterized in that the slightly oriented, coarse titer filaments and other filaments are present in a practically homogeneous mixture. 7. Nonwoven fabric according to at least one of claims 1 to 5, characterized characterized in that the poorly oriented, coarse titer filaments and other filaments predominantly in different layers of the Nonwoven fabric that are mechanically interconnected.   8. Nonwoven fabric according to at least one of claims 1 to 7, characterized characterized in that the basis weight of the nonwoven in the area from 50 to 500 g per m², preferably from 100 to 300 g per m² lies. 9. Nonwoven fabric according to at least one of claims 1 to 8, characterized characterized in that the nonwoven fabric additionally with another known non-woven fabric combined and selectively or over the entire surface connected is. 10. The method for producing the spunbonded fabric of claim 1 by Depositing the filaments into a tangled nonwoven in a manner known per se, characterized in that at least 30% by weight of poorly oriented, coarse titre filaments are deposited, the individual titers of over 7 dtex lies and the bonding of the fleece takes place purely mechanically. 11. The method according to claim 10, characterized in that the Filament deposit by several in the direction of movement Fleece transport device one behind the other rows of Filing organs that are alternately slightly oriented, coarse-titled and deposit other filaments. 12. Isotropic, deep-drawing nonwoven according to at least one of the Claims 1 to 9, characterized in that it additionally with is impregnated with a thermoplastic or thermosetting resin. 13. Thermoformable nonwoven fabric according to claim 12, characterized in that that the resin pad is dimensioned so that there is essentially one open-pored nonwoven network results. 14. Process for the production of the thermoformable resin-impregnated Nonwoven fabric of claim 12, characterized in that according to Claim 10 produces a thermoformable nonwoven, and this then with a thermoplastic or thermosetting resin  impregnated. 15. Three-dimensionally deformed, open-pore nonwoven, thereby characterized in that at least 30% by weight of the filaments is low oriented, coarse titre filaments that are also in the deformed Areas are only stretched to below their maximum tensile strength. 16. Three-dimensionally deformed open-pore nonwoven fabric according to claim 15, characterized in that it is additionally coated with a thermoplastic or thermosetting resin is stiffened. 17. Process for producing the three-dimensionally deformed nonwoven of claim 15, characterized in that one thermoformable nonwoven fabric of claim 1 by a thermoforming process with a regular arrangement of a large number of surveys and Provides recesses. 18. Process for producing the three-dimensionally deformed resin-stiffened nonwoven fabric of claim 16, characterized in that together a thermoformable nonwoven fabric of claim 1 with a resin film through a deep drawing process with a regular Arrangement of a variety of elevations and depressions provided. 19. Process for producing the three-dimensionally deformed nonwoven Claim 16, characterized in that one three-dimensionally shaped nonwoven fabric by the process of Claim 17 produces, and then this with a impregnated thermoplastic or thermosetting resin and if necessary cures. 20. Process for producing the three-dimensional deformed nonwoven of claim 16, characterized in that one thermoformable resin-impregnated nonwoven fabric of claim 12, by  a deep drawing process with a regular arrangement of a variety provided by elevations and depressions. 21. Flat sandwich molded body consisting of two outer solid cover layers that have a core of light material are connected, characterized in that the core from the three-dimensionally deformed, resin-stiffened fleece of claim 16 consists. 22. A method for producing the sandwich molded body of claim 21, characterized in that according to one of claims 17 to 20 a three-dimensionally deformed, resin-stiffened fleece is produced and opened this then covers the cover layers on both sides in a manner known per se Laminated way.