EP0703307A1 - Textile composite, textile composite pocket and method of producing a composite part from such a textile or pocket - Google Patents

Abstract

A composite textile (1), partic. destined to be coated with an impregnating resin, consists of an extensible film (2) with the reverse face (2a) being completely covered with a felt (3) of preformed glass fibre agglomerated by a thermoplastic binder, and a sheet (4) of non-woven glass fibre. The extensible-film (2) is partic. polyether or polyester polyurethane, or polyamide; between 25 micron and 1 mm thick, pref. about 50 microns. The fibre glass felt may be of several layers and different types. Composite textile pockets (5) are made by joining film face to film face two layers of composite textile. These are partic. for filling with polymerisable material partic. polyurethane foam either filled or with metallic agents.

Description

The invention relates to a composite textile, a composite textile pocket and a method of manufacturing a composite part from such a composite textile and / or from such a composite textile pocket.

The invention finds an application in particular whenever it is desired to manufacture a composite part having good mechanical strength for a low weight.

• . injection dans un moule d'un pain de mousse de polyuréthanne et généralement d'un agent de démoulage ;
• . ébavurage de ce pain de mousse de polyuréthanne ;
• . Dérochage, c'est-à-dire sablage de surface pour enlever l'agent de démoulage et préparer la surface du pain de mousse de polyuréthanne pour permettre l'accrochage mécanique de la résine d'enrobage ;
• . découpe d'un non tissé de fibres de verre ;
• . préformage mécanique ou thermique de cette découpe ou revêtement à la main ;
• . agrafage ou soudage à chaud ;
• . pose du voile de finition ;
• . enfin, injection de la résine.

Processes for manufacturing composite parts are already known. Generally, these consist of a succession of steps heavy in manpower and costs. Thus, such known manufacturing methods consist of the following succession of steps:

• . injection into a mold of a polyurethane foam bar and generally of a release agent;
• . deburring of this polyurethane foam bread;
• . Removal, that is to say surface sanding to remove the release agent and prepare the surface of the polyurethane foam bread to allow mechanical attachment of the coating resin;
• . cutting a nonwoven of glass fibers;
• . mechanical or thermal preforming of this cut or coating by hand;
• . stapling or hot welding;
• . installation of the finishing veil;
• . finally, injection of the resin.

As mentioned above, such manufacturing methods known from the prior art require abundant labor and generate significant production costs.

In addition, during this type of process, the handling of the polyurethane foam bread coated with the glass fiber nonwoven is made very difficult given that the latter is associated with bread by simple stapling.

To this end, the object of the invention is to propose a method of manufacturing composite parts which overcomes the drawbacks or limits of those known in the art.

Another object of the present invention is to provide a composite textile and a pocket of composite textile whose use in the process for manufacturing the composite parts according to the invention makes it possible to greatly reduce the number of steps in the process and, thereby even, to speed up manufacturing.

To do this, the invention firstly proposes a composite textile, intended in particular to be coated with a coating resin, characterized in that it comprises an extensible film comprising a front face and a back face, the face front being covered substantially over its entire length successively with at least one felt of preformable glass fibers agglomerated by a thermoplastic binder and at least one nonwoven veil of glass fibers.

The invention also provides a pocket of composite textile intended in particular to be coated with a coating resin, characterized in that it consists of two composite textiles secured to each other by the back side of the extensible film along a joining line .

• . fabriquer un textile composite en disposant successivement sur un plan de travail le film extensible, au moins le feutre de fibres de verre préformable agglomérées par un liant thermoplastique et au moins le voile de non tissé de fibres de verre, en chauffant le textile composite ainsi obtenu puis en le refroidissant ;
• . fabriquer une poche de textile composite en superposant deux textiles composites par leur face verso de film puis en les solidarisant selon une ligne de solidarisation en rapport avec la forme de la pièce que l'on cherche à fabriquer ;
• . effectuer une découpe des textiles composites en périphérie de la ligne de solidarisation ;
• . disposer la poche de textile composite ainsi obtenue dans un moule de manière à ce qu'elle soit contenue dans le moule mais non maintenue ;
• . injecter une matière polymérisable dans ladite poche de textile composite ;
• . refroidir ladite poche ainsi remplie pour obtenir une pièce composite prête à subir une injection de résine d'enrobage ;
• . et/ou injecter une résine d'enroubage dans ledit moule.

The invention finally proposes a method for manufacturing a composite part, characterized in that it comprises the successive stages consisting in:

• . fabricating a composite textile by successively placing on the work surface the extensible film, at least the felt of preformable glass fibers agglomerated by a thermoplastic binder and at least the non-woven veil of glass fibers, by heating the composite textile thus obtained then by cooling it;
• . make a composite textile pocket out of superimposing two composite textiles by their back side of film and then joining them together along a joining line in relation to the shape of the part that one seeks to manufacture;
• . cut the composite textiles around the periphery of the joining line;
• . placing the pocket of composite textile thus obtained in a mold so that it is contained in the mold but not maintained;
• . injecting a polymerizable material into said pocket of composite textile;
• . cooling said pocket thus filled to obtain a composite part ready to undergo an injection of coating resin;
• . and / or inject a coating resin into said mold.

Thus, it appears that the invention allows, by the use of a composite textile of a particular structure and a pocket made from this composite textile, the easy, reliable and economical manufacture of any type of composite part. .

• . La figure 1 est une vue schématique en coupe d'un textile composite conforme à la présente invention ;
• . La figure 2 est une vue schématique en coupe d'une poche de textile composite conforme à la présente invention.

Other characteristics and advantages of the invention will be clearly understood on reading the description which follows with reference to the appended drawings in which:

• . Figure 1 is a schematic sectional view of a composite textile according to the present invention;
• . Figure 2 is a schematic sectional view of a pocket of composite fabric according to the present invention.

The invention therefore relates to the field of composite parts. Such parts find their application whenever one wishes parts having good mechanical strength for a low weight. These parts are generally intended to be coated with a resin coating, then possibly, lacquer, varnish, paint or equivalent.

A typical example of the use of such parts can be found in the field of the automotive industry: these are car fins.

The invention therefore relates first of all to a composite textile 1 characterized in that it comprises an extensible film 2 comprising a front side 2a and a back side 2b, the front side 2a being covered substantially over its entire length successively at least at least one felt 3 of preformable glass fibers agglomerated by a thermoplastic binder and at least one veil 4 of nonwoven of glass fibers.

This composite textile allows the production of a pocket which, according to the invention consists of two composite textiles 1 secured to each other by the back side 2b of the film 2 which can be extended along a joining line 6.

This pocket, as we will see below, is intended to be filled with a polymerizable material, then coated with a coating resin.

Each of the components of the composite textile was chosen to facilitate the implementation of the manufacturing process which will be described below.

The veil 4, consisting of a nonwoven of extremely compacted glass fibers, has as its first function that of finishing. By playing the role of mechanical barrier, it prevents the coarse glass fibers of the felt 3 from appearing on the surface of the composite part made from the composite textile. It therefore improves the finish appearance of the surface of the composite part which will subsequently receive the coating resin. Consequently, it is obviously necessary for this veil 4 of nonwoven and of glass fibers to be able to withstand the conditions of injection of the coating resin.

The felt 3 of glass fibers is preformable, which makes it possible to use, at the time of the actual molding, a reinforcement which is already in the shape of the part to be manufactured.

The felt 3 of glass fibers is also agglomerated by a thermoplastic binder, which allows on the one hand its association with the extensible film 2 and on the other hand, improves the preformability of the felt 3.

This felt 3 can be made up of several layers of glass fibers of different titles. Thus, by way of indication, the felt 3 may consist of a layer of 50 tex threads sandwiched between two layers of 25 tex threads.

The felt 3 of glass fibers can also comprise a metallic insert such as for example electric pins, a plastic or composite insert.

• . il doit présenter une adhérence par rapport à la résine d'enrobage et au feutre 3 de fibres de verre ;
• . il doit présenter une adhérence par rapport à la matière polymérisable avec laquelle il sera mis en contact lors de la fabrication de la pièce composite ;
• . il doit être étanche à cette même matière polymérisable ;
• . il doit être extensible compte tenu du fait que, lors de l'injection de la matière polymérisable, le textile composite passera d'une forme à deux dimensions à une forme à trois dimensions ;
• . enfin, il doit pouvoir être lié par chauffage ou par des moyens physico-chimiques.

The nature and the thickness of the film 2 partially composing the composite textile according to the invention are chosen so as to fulfill the following specifications:

• . it must have adhesion with respect to the coating resin and to the felt 3 of glass fibers;
• . it must have an adhesion with respect to the polymerizable material with which it will be brought into contact during the manufacture of the composite part;
• . it must be impervious to the same polymerizable material;
• . it must be extensible taking into account that, during the injection of the polymerizable material, the composite textile will pass from a two-dimensional shape to a three-dimensional shape;
• . finally, it must be able to be bonded by heating or by physico-chemical means.

To this end, according to the invention, the film 2 is thermoplastic. It has a thickness between 25 μm and approximately 1 mm, preferably of the order of 50 μm and can be multilayer.

In a preferred variant of the invention, the film 2 is composed of polyesterurethane. However, it can also be based on polyetherurethane or polyamide, the main thing being that it fulfills the specifications defined above.

This composite textile 1 is intended to be used in the form of a pocket 5 which, during the process for manufacturing the composite part, will be filled with a polymerizable material.

In a preferred variant of the invention, this polymerizable material is a polyurethane foam with a density of between 0.1 and 0.9 g / cm³ and, preferably, between 0.3 and 0.4 g / cm³. However, depending on the use to be made of the composite part, this polymerizable material can be of any type such as, in particular, polyvinyl chloride (PVC).

Also, depending on the end use of the composite part, the formulation of the polyurethane foam can be adapted to have a skin effect, that is to say to have a high density on the surface and a lower density at the heart.

The polymerizable material can also comprise a metallic, plastic or composite insert and it can be loaded for example with glass or ceramic microbeads or glass microfibers.

• a) une étape de fabrication du textile composite 1 ;
• b) une étape de fabrication d'une poche 5 de textile composite ;
• c) une étape de préparation de la poche de textile composite en vue de l'injection de la matière polymérisable ;
• d) une étape d'injection de la matière polymérisable dans ladite poche 5 ;
• e) une étape d'injection d'une résine d'enrobage.

The invention also relates to a method of manufacturing a composite part essentially comprising five steps:

• a) a step of manufacturing the composite textile 1;
• b) a step of manufacturing a pocket 5 of composite textile;
• c) a step of preparing the pocket of composite textile for the injection of the polymerizable material;
• d) a step of injecting the polymerizable material into said pocket 5;
• e) a step of injecting a coating resin.

a) MANUFACTURE OF COMPOSITE TEXTILE 1:

The composite textile 1 according to the invention is manufactured by successively placing on a work surface (which may possibly be a mold) the extensible film 2, at least the felt 3 of preformable glass fibers agglomerated by a thermoplastic binder and at least the veil 4 of glass fiber nonwoven.

The veil 4 of non-woven glass fibers can be placed, not at this stage, but at the time of the stage of manufacturing the pocket 5 of composite textile.

The composite fabric 1 is then heated by passage through an oven (radiant, hot air, etc.) to a temperature between 80 and 110 ° C. This heating allows on the one hand the thermoplastic binder of the felt 3 to act, and, on the other hand, the thermoplastic film 2 to soften, the result of this heating being the intimate association of the web 4 of nonwoven fibers of glass, of the felt 3 of glass fibers and of the thermoplastic film 2.

Following this heating, the composite textile 1 can be cooled and stored.

b) MANUFACTURE OF COMPOSITE TEXTILE POCKET 5:

This step consists in superimposing two composite textiles 1 obtained in the previous step, by their back sides 2b of film 2, then in joining them together along a joining line 6 in relation to the shape of the composite part that is to be sought. to manufacture.

This joining of the two composite textiles 1 is carried out by welding means (heating, high frequency, ultrasound) or by bonding means (polyurethane glue, silicone, mastic).

Simultaneously or not at the joining step, a composite textiles 1 is then cut at the periphery of the joining line 6. This cutting is carried out at a distance of the order of 2 to 3 cm from the joining line 6 .

• . Avant les étapes de solidarisation et de découpe, on positionne des canules d'injection de manière à ce qu'elles soient à cheval sur la ligne de solidarisation 6 lors de l'étape de solidarisation pour permettre ainsi leur emprisonnement ;
• . Ou bien, lors de l'étape de solidarisation, on laisse des réserves non solidarisées destinées à recevoir lesdites canules d'injection.

Furthermore, in addition to the introduction of the polymerizable material into the pocket 5 of composite textile and for the evacuation of the gas following this injection, there are provided two alternative embodiments in the manufacturing process according to the present invention:

• . Before the joining and cutting steps, injection cannulas are positioned so that they are astride the joining line 6 during the joining step to thereby allow their imprisonment;
• . Or, during the joining step, non-joined reserves are left intended to receive said injection cannulas.

c) PREPARATION OF THE COMPOSITE TEXTILE POCKET 5:

This step consists in placing the pocket 5 of composite textile obtained by the previous step in a mold so that it is contained in the mold but not maintained. This mold can be made up of several movable or removable parts making it possible to facilitate and ensure proper placement of the bag 5, said parts being folded down before or during the injection of the polymerizable material.

Also, during this step, the floating periphery 7 of the pocket 5 of composite textile is folded towards the center of said pocket.

d) INJECTION OF THE POLYMERIZABLE MATERIAL:

Before the actual injection of the material polymerizable, first of all a depressurization of the pocket 5 of composite textile is carried out to press it against the mold. Then, after injection, a vacuum is made in the mold to help the extension of the polymerizable material and so that it takes all the shape of the mold imprint.

During these steps, we work with molds heated to a temperature between 50 and 80 ° C so as to initiate the polymerization reaction of the polymerizable material and to promote the thermoforming effect of the glass fibers of the felt 3 and of the veil 4.

It is also advisable to use metal molds taking into account this temperature of use and the abrasive effect of the glass fibers.

After this step, cutting the cores of polymerizable material may possibly be necessary.

After cooling, a composite part is obtained ready to undergo an injection of coating resin.

e) INJECTION OF THE COATING RESIN

According to a variant of the process according to the invention, a coating resin can be injected directly after the injection of polymerizable material and therefore before the cooling mentioned above. To this end, the residual injection core is cut from the injection of polymerizable material, without removing the part from the mold, then the coating resin is injected into the felt 3 of glass fibers. This injection is carried out at a temperature of 80 ° C. under a pressure of 30 bars. After polymerization, a finished composite part is obtained, that is to say coated with resin. Obviously, the mold and the polymerizable material must be able to withstand a pressure of 30 bars.

• . Voile de non tissé de fibres de verre
• . Feutre de fibres de verre : MAT UNIFILO U 750 commercialisé par la société VETROTEX
     Masse surfacique : 375 g/m²
• . Film thermoplastique : WALOPUR 2201 AU commercialisé par la société WOLFF WALSRODE
     Densité : 1,14 g/cm3
     Plage de ramollissement : 145 - 155°C
     Dureté shore A : 85
     Epaisseur : 25 µm
     Mousse de polyuréthanne : ELASTOLIT (marque déposée) ED 9031/1 commercialisée par la société ELASTOGRAN.

The present invention will now be illustrated in using an example given as an indication and not limiting of a manufacture of a motor vehicle spoiler:

• . Glass fiber nonwoven veil
• . Glass fiber felt: MAT UNIFILO U 750 sold by the company VETROTEX
  Area weight: 375 g / m²
• . Thermoplastic film: WALOPUR 2201 AU sold by the company WOLFF WALSRODE
  Density: 1.14 g / cm3
  Softening range: 145 - 155 ° C
  Shore A hardness: 85
  Thickness: 25 µm
  Polyurethane foam: ELASTOLIT (registered trademark) ED 9031/1 sold by the company ELASTOGRAN.

Claims (30)

Composite textile (1) intended in particular to be coated with a coating resin, characterized in that it comprises an extensible film (2) comprising a front side (2a) and a back side (2b), the front side (2a) being covered substantially over its entire length, successively with at least one felt (3) of preformable glass fibers agglomerated by a thermoplastic binder and at least one veil (4) of nonwoven of glass fibers. Composite textile according to claim 1, characterized in that the nature and the thickness of the film (2) are chosen so that it has adhesion with respect to the coating resin and to the felt (3) of glass fibers. Composite textile according to claim 1 or 2, characterized in that the film (2) is thermoplastic. Composite textile according to any one of claims 1 to 3, characterized in that the film (2) has a thickness of between 25 µm and approximately 1 mm, preferably of the order of 50 µm. Composite textile according to any one of claims 1 to 4, characterized in that the film (2) is multilayer. Composite textile according to any one of claims 1 to 5, characterized in that the film (2) is composed of polyesterurethane, polyetherurethane or polyamide. Composite textile according to any one of claims 1 to 6, characterized in that the felt (3) consists of several layers of glass fibers of different titles. Composite textile according to any one of Claims 1 to 7, characterized in that the felt (3) comprises a metallic, plastic or composite insert. Pouch (5) of composite textile intended in particular to be coated with a coating resin, characterized in that it consists of two composite textiles (1) according to any one of claims 1 to 8 secured to each other by the reverse side (2b) of the film (2) extendable along a joining line (6). Pouch (5) of composite textile according to claim 9, characterized in that it is filled with a polymerizable material. Pouch (5) of composite textile according to claim 10, characterized in that the polymerizable material is a polyurethane foam. Pouch (5) of composite textile according to claim 11, characterized in that the formulation of the polyurethane foam is adapted to have a skin effect. Composite textile bag (5) according to any one of Claims 10 to 12, characterized in that the polymerizable material comprises a metallic, plastic or composite insert. Pouch (5) of composite textile according to any one of claims 10 to 13, characterized in that the polymerizable material is loaded. Method for manufacturing a composite part, characterized in that it comprises the successive stages consisting in: . manufacturing a composite textile (1) according to any one of claims 1 to 8 by successively placing on a work surface the extensible film (2), at least the felt (3) of preformable glass fibers agglomerated by a thermoplastic binder and at least the veil (4) of non-woven glass fibers, by heating the composite textile (1) thus obtained then by cooling it; . fabricate a pocket (5) of composite textile superimposing two composite textiles (1) by their back side (2b) of film (2) then by joining them together along a joining line (6) in relation to the shape of the part that one is seeking to manufacture; . cutting the composite textiles (1) around the periphery of the joining line (6); . placing the pocket (5) of composite textile thus obtained in a mold so that it is contained in the mold but not maintained; . injecting a polymerizable material into said pocket (5) of composite textile; . cooling said pocket (5) thus filled to obtain a composite part ready to undergo an injection of coating resin; . and / or injecting a coating resin into said mold. Method according to claim 15, characterized in that the composite textile (1) is heated to a temperature between 80 ° C and 110 ° C during its manufacture. Method according to claim 15 or 16, characterized in that the composite textile (1) is stored before the production of the pocket (5). Method according to any one of claims 15 to 17, characterized in that during the production of the pocket (5), the two composite textiles (1) are joined together by means of welding, gluing or the like. Method according to any one of Claims 15 to 18, characterized in that the joining and cutting steps take place simultaneously. Process according to any one of Claims 15 to 19, characterized in that the cutting is carried out at a distance of the order of 2 to 3 cm from the joining line. Method according to any one of claims 15 to 20, characterized in that before the joining and cutting steps, injection cannulas are positioned so that they are astride the joining line ( 6) during the joining stage and thus be imprisoned. A method according to any one of claims 15 to 20, characterized in that during the joining step, leaving unconnected reserves intended to receive injection cannulas. Process according to any one of Claims 15 to 22, characterized in that the step of injecting the polymerizable material is preceded by a step of depressurizing the pocket (5) of composite textile. Process according to any one of Claims 15 to 23, characterized in that a vacuum is made in the mold after the injection of the polymerizable material to aid in its expansion. Process according to any one of Claims 15 to 24, characterized in that it works with molds heated to a temperature between 50 and 80 ° C. Process according to any one of Claims 15 to 25, characterized in that the polymerizable material is a polyurethane foam. Method according to claim 26, characterized in that the formulation of the polyurethane foam is adapted to have a skin effect. Method according to one of claims 26 or 27, characterized in that the polymerizable material comprises a metallic, plastic or composite insert. Method according to any one of Claims 26 to 28, characterized in that the polymerizable material is charged. Process according to any one of Claims 15 to 29, characterized in that a mold is used which has movable or removable parts.

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