EP0737763A2 - Production and application of a permanently deformable textil material made out of hybrid yarn - Google Patents

Abstract

Hybrid yarn comprises: (A) reinforcing filaments with: (i) an initial modulus of more than 600 (800-25,000, pref. 2000-20,000) cN/tex; (ii) a max. tensile strength of more than 60 (80-220, pref. 100-200) cN/tex; (iii) a max. elongation of 0.01-20 (0.1-7.0 pref. 1-5) %; and (iv) a degree of crimping of 5-60 (12-50, pref. 18-36) %; and (B) thermoplastic matrix filaments with a m.pt. at least 10 (20-100, pref. 30-70) degrees C below the m.pt. of (A). Also claimed are: (i) permanently ductile textile sheet contg. an amt. of hybrid yarn sufficient to have a significant effect on the ductility of the sheet; (ii) fibre-reinforced mouldings; (iii) a process for the prodn. of hybrid yarn from components (A) and (B) in a swirling or blow-texturing system in which at least (A) is introduced with an overfeed of 5-60%; (iv) a process for the prodn. of textile sheet as above (i) by weaving, knitting, laying or matting; and (v) a process for the prodn. of mouldings as above (ii) by forming textile sheet (i) at a temp. above the m.pt. of (B) and below the m.pt. of (A).

Description

The present invention relates to a hybrid yarn containing reinforcing filaments and thermoplastic matrix filaments, and permanently deformable, e.g. deep-drawable, textile fabrics. Furthermore, the invention relates to the fiber-reinforced thermoplastic molded articles produced by deforming the deformable textile surfaces according to the invention, which, due to the unidirectional or multidirectionally arranged, essentially elongated reinforcing filaments, have a selectively adjustable high strength in one or more directions.

Hybrid yarns made from infusible (e.g. glass or carbon fiber) and meltable fibers (e.g. polyester fiber) are known. For example, patent applications EP-A-156 599, 156 600, 351 201 and 378 381 and Japanese publication JP-A-04 353 525 relate to hybrid yarns made from non-meltable fibers, for example glass fibers, and thermoplastic, for example polyester fibers.
EP-A-551 832 and DE-A-29 20 513 also relate to mixed yarns which, however, are bonded, but are previously present as hybrid yarns.

It is also known from hybrid yarns which have a high-melting or infusible filament portion and a thermoplastic lower-melting filament portion to produce fabrics which are heated to above the melting point of the thermoplastic, lower-melting yarn component in fiber-reinforced, rigid thermoplastic sheets, so-called "organic sheets". can be transferred.

Different ways of producing fiber-reinforced thermoplastic semi-finished products have been described in chemical fibers / textile technology 39/91. Volume (1989) pages T185 to T187, T224 to T228 and T236 to T240. The production starting from sheet-like textile materials from hybrid yarns is described there as an elegant way, which offers the advantage that the mixing ratio of reinforcement and Matrix fibers can be adjusted very precisely and that the textile materials can be easily inserted into press molds due to their drapability (chemical fibers / textile technology, 39th / 91st year (1989), page T186).
As can be seen from page T238 / T239 of this publication, problems arise with the two-dimensional deformation of the textile materials. Since the elasticity of the reinforcement threads is usually negligible, textile surfaces made of conventional hybrid yarns can only be deformed due to their binding.
However, this deformability is usually limited if wrinkles are to be avoided (T239), an experience that has been confirmed by computer simulations.
The way out of pressing the textiles from reinforcing and matrix threads into molds has the disadvantage that a partial compression then occurs, which leads to a displacement and / or crimping of the reinforcing threads combined with a decrease in the reinforcing effect.
Another possibility mentioned in page T239 / T240 to produce three-dimensionally deformed molded parts with undisplaced reinforcing threads would be the production of three-dimensionally woven preforms, but this requires considerable mechanical expenditure, both in the production of the preforms and in the thermoplastic impregnation or coating .

A fundamentally different way of producing fiber-reinforced thermoplastic molded articles is to produce a textile surface which essentially consists only of reinforcing yarns, to insert them as a whole or in the form of smaller sections into molds or to place them on molds, with a melted or in a solution or To disperse the dispersing agent dissolved or dispersed matrix resin and to harden the resin by cooling or evaporation of the solvent or dispersing agent.
This method can also be varied in such a way that the reinforcing textile is impregnated into or onto the mold before it is placed or laid on and / or that the reinforcing textile and a thermoplastic matrix resin are pressed into the desired shape in closed molds under pressure, one Working temperature is selected in which the matrix resin flows and encloses the reinforcing fibers without gaps.
Reinforcing textiles for this technology are known for example from DE-GBM 85 21 108. The material described there consists of superimposed longitudinal and transverse thread layers which are connected to one another by additional longitudinal threads made of thermoplastic material.
A similar reinforcement textile material is known from EP-A-0 144 939.
The textile reinforcement consists of warp and weft threads, which are wrapped with threads made of thermoplastic material, which cause the reinforcing fibers to be welded together by heating.

Another reinforcing textile material is known from EP-A-0 268 838. This also consists of a layer of longitudinal threads and a layer of transverse threads, which are not interwoven, but one of the thread layers is said to have a significantly higher heat-shrinking capacity than the other. In the material known from this document, the cohesion is achieved by means of auxiliary threads which do not glue the layers of the reinforcing threads but instead fix them loosely to one another so as to be displaceable.

A method known from DE-A-40 42 063 is used to improve the deformability of reinforcing inserts. In this, length-deformable, namely heat-shrinking, auxiliary threads are incorporated into the fabric provided as textile reinforcement. The shrinkage is triggered by heating and the textile material is contracted somewhat, so that the reinforcing threads are curled or held in a loose wrap.

DE-A-34 08 769 discloses a method for producing fiber-reinforced molded articles made of thermoplastic material, in which flexible textile structures are used which consist of largely unidirectionally oriented reinforcing fibers and a matrix made up of thermoplastic yarns or fibers. These semi-finished products are deformed in their final shape by heatable profile nozzles, practically all of them thermoplastic fibers are melted.

A layered semi-finished product for the production of fiber-reinforced thermoplastic molded articles is known from EP-A-0 369 395. This material consists of a thermoplastic layer in which a multiplicity of spaced parallel reinforcing threads with very low elongation at break is embedded, which have deflections at regular intervals, which form a thread reservoir. When these layered semi-finished products are deformed, the deflections of the reinforcing threads are drawn straight, as a result of which tearing is avoided.

From the point of view of production technology, those semi-finished products are most advantageous which have a textile character, ie which are drapable, and which contain both the reinforcing fibers and the matrix material.
Those that have a precisely defined weight ratio of reinforcing fibers to matrix material would be particularly advantageous.
The previously known drapable semi-finished products, which have a defined ratio of reinforcing fibers and matrix material, can indeed be placed in compression molds and pressed into shaped bodies, but often do not have the ideal arrangement and extension of the reinforcing fibers after the deformation because of the compression during pressing.
Reinforcing inserts, such as those known from DE-A-40 42 063, are indeed three-dimensionally deformable, for example by deep drawing, whereby the desired arrangement and stretching of the reinforcing fibers can generally be achieved, but must be embedded in the matrix material in an additional operation become.
Deep-drawable fiber-reinforced semifinished products, such as those known from EP-A-0 369 395, are difficult to produce because of the complicated undulating arrangement of the reinforcing yarns.

It has now been found that the disadvantages of the prior art can be largely overcome by means of a sheet-like semifinished product which has a textile character, is permanently deformable, for example deep-drawing, and contains both the reinforcing fibers and the matrix material in a defined weight ratio.

Such an advantageous semi-finished product can be produced by weaving, knitting or knitting, but also by cross-laying or other known processes for the production of sheet-like textiles on known machines, starting from a hybrid yarn which is an object of this invention.

For the purposes of this invention and in the following description, the terms "fibers", "fiber materials", "fiber components" and terms composed with these terms also mean "filaments", "filament materials", filament components "and terms combined therewith "Fiber or filament components" are not to be understood as the chemical components of the fibers or filaments, but rather the fibrous or filament components of the hybrid yarns, semifinished products and fiber-reinforced thermoplastic molded articles according to the invention.

• die Filamente (A) der ersten Gruppe einen Anfangsmodul von über 600 cN/tex, vorzugsweise von 800 bis 25000 cN/tex, insbesondere von 2000 bis 20000 cN/tex,
  eine feinheitsbezogene Höchstzugkraft von über 60 cN/tex, vorzugsweise von 80 bis 220 cN/tex, insbesondere von 100 bis 200 cN/tex
  und eine Höchstzugkraftdehnung von 0,01 bis 20%, vorzugsweise von 0,1 bis 7,0 %, insbesondere von 1,0 bis 5,0 % haben
• die Filamente (B) der zweiten Gruppe Thermoplastfilamente sind, die einen Schmelzpunkt haben, der mindestens 10 °C, vorzugsweise 20 bis 100 °C, insbesondere 30 bis 70 °C unter dem Schmelzpunkt der Filamente (A) liegt,
• die Filamente (A) eine Einkräuselung von 5 % bis 60 %, vorzugsweise von 12 bis 50 % insbesondere von 18 bis 36 % haben.

The hybrid yarn according to the invention consists of two groups of filaments, one group consisting of one or more types of reinforcing filaments (filaments (A)) and the other group consisting of one or more types of matrix filaments (filaments (B)), characterized in that

• the filaments (A) of the first group have an initial modulus of over 600 cN / tex, preferably from 800 to 25000 cN / tex, in particular from 2000 to 20,000 cN / tex,
  a fineness-related maximum tensile force of over 60 cN / tex, preferably from 80 to 220 cN / tex, in particular from 100 to 200 cN / tex
  and have a maximum tensile elongation of 0.01 to 20%, preferably 0.1 to 7.0%, in particular 1.0 to 5.0%
• the filaments (B) of the second group are thermoplastic filaments which have a melting point which is at least 10 ° C., preferably 20 to 100 ° C., in particular 30 to 70 ° C. below the melting point of the filaments (A),
• the filaments (A) have a crimp of 5% to 60%, preferably of 12 to 50%, in particular of 18 to 36%.

The filaments are expediently intermingled with one another. This has the advantage that the hybrid yarn can be more easily processed into flat materials on conventional machines because of the improved thread closure, for example woven into or knitted, and that in the manufacture of fiber-reinforced thermoplastic molded articles from the sheet-like textile material, because of the intimate mixture of the reinforcing and matrix fibers, very short flow paths of the melted matrix material and an excellent gapless embedding of the reinforcement filaments in the thermoplastic matrix result.
The degree of swirling is expediently at an opening length, measured with an ITEMAT needle tester (according to US-A-2985995), of <200 mm, preferably in the range from 5 to 100 mm, in particular in the range from 10 to 30 mm.

The fibers of type (A) have a crimp, i.e. they form a series of small or large arches. "Crimp" in the sense of this invention is to be understood as the undrawn, undulating course of the filaments (A) in the hybrid yarn, which is brought about by the fact that the length of the filaments (A) is greater than the length of the yarn in which they are contained.

The hybrid yarn according to the invention expediently has a total denier from 100 to 25,000 dtex, preferably from 150 to 15,000 dtex, in particular from 200 to 10,000 dtex.

The proportion of filaments (A) is 20 to 90, preferably 35 to 85, in particular 45 to 75% by weight,
the proportion of filaments (B) 10 to 80, preferably 15 to 45, in particular 20 to 55% by weight and the proportion of further fiber components 0 to 70, preferably 0 to 50, in particular 0 to 30% by weight of the hybrid yarn according to the invention.

The proportion of thermoplastic fibers (B), the melting point of which is at least 10 ° C. lower than the melting point of the reinforcing fibers (A), is 10 to 80, preferably 15 to 45, in particular 20 to 40% by weight of the hybrid yarn according to the invention.

The filaments (A) which form the reinforcing filaments in the end product, ie the fiber-reinforced three-dimensional thermoplastic molded body, advantageously have a dry heat shrinkage maximum of less than 3%.
These filaments (A) expediently have an initial modulus of over 600 cN / tex, preferably from 800 to 25000 cN / tex, in particular from 2000 to 20,000 cN / tex,
a fineness-related maximum tensile force of over 60 cN / tex, preferably from 80 to 220 cN / tex, in particular from 100 to 200 cN / tex
and a maximum tensile elongation of 0.01 to 20%, preferably 0.1 to 7.0%, in particular 1.0 to 5.0%.

In the interest of a typical textile character with good drapability, the filaments (A) have individual titers of 0.1 to 20 dtex, preferably 0.4 to 16 dtex, in particular 0.8 to 10 dtex.
In cases where drapability is not important, reinforcement filaments with individual titers greater than 20 dtex can also be used.

The filaments (A) are either inorganic filaments, or filaments made of so-called high-performance polymers or pre-shrunk and / or fixed organic filaments made of other organic polymers suitable for producing high-strength filaments.

Examples of inorganic filaments are glass filaments, carbon filaments, filaments made of metals or metal alloys such as steel, aluminum or tungsten; Non-metals such as boron; or metal or non-metal oxides, carbides or nitrides, such as aluminum oxide, zirconium oxide, boron nitride, boron carbide or silicon carbide; Ceramic filaments, filaments made of slag, stone or quartz.
Preferred inorganic filaments (A) are metal, glass, ceramic or carbon filaments, in particular glass filaments.

Glass filaments used as filaments (A) preferably have titers of 0.15 to 3.5 dtex, in particular 0.25 to 1.5 dtex.

Filaments made of high-performance polymers in the sense of this invention are filaments made of polymers which, without or with only slight stretching, possibly after a heat treatment after the spinning process, deliver filaments with a very high initial modulus and very high tensile strength (= fineness-related maximum tensile strength). Such filaments are described in detail in Ullmann's Encyclopedia of Industrial Chemistry, 5th edition (1989), volume A13, pages 1 to 21 and volume 21, pages 449 to 456. They consist, for example, of liquid-crystalline polyesters (LCP), poly (bis- benzimidazo-benzophenanthroline) (BBB), poly (amide imidene) (PAI), polybenzimidazole (PBI), poly (p-phenylene benzobisoxazole) (PBO), poly (p-phenylene benzo bisthiazole) (PBT), Polyether ketone (PEK), polyether ether ketone (PEEK), polyether ether ketone ketone (PEEKK), polyetherimides (PEI), polyether sulfone (PESU), polyimides (PI), aramids such as poly- (m-phenylene-isophthalamide) (PMIA), poly- (m- phenylene terephthalamide) (PMTA), poly (p-phenylene isophthalamide) (PPIA), poly (p-phenylene pyromellitimide) (PPPI), poly (p-phenylene) (PPP) poly (phenylene sulfide) ( PPS), poly (p-phenylene terephthalamide) (PPTA) or polysulfone (PSU).

The filaments (A) are preferably pre-shrunk and / or fixed aramid, polyester, polyacrylonitrile, polypropylene, PEK, PEEK or polyoxymethylene filaments, in particular pre-shrunk and / or fixed aramid filaments or high modulus polyester filaments.

The filaments (B) have an initial modulus of over 200 cN / tex, preferably from 220 to 650 cN / tex, in particular from 300 to 500 cN / tex
a fineness-related maximum tensile force of over 12 cN / tex, preferably from 25 to 70 cN / tex, in particular from 30 to 65 cN / tex
and a maximum tensile strength elongation of 20 to 50%, preferably 15 to 45%, in particular 20 to 35%.
Depending on the required pliability (drapability) of the semi-finished product, they have individual titers of 0.5 to 25 dtex, preferably 0.7 to 15 dtex, in particular 0.8 to 10 dtex.

The filaments (B) are synthetic organic filaments.

Insofar as they have the required above-mentioned melting point difference of at least 10 ° C., preferably 20 to 100 ° C., in particular 30 to 70 ° C., compared to the filaments (A), they can consist of the above-mentioned high-performance polymers. Filaments (B) made of polyetherimide (PEI) may be mentioned as an example if the filaments (A) e.g. are made of glass.

Other spinnable polymers such as, for example, can also be considered as the polymer material from which the filaments (B) are made
Vinyl polymers such as polyolefins, polyvinyl esters, polyvinyl ethers, polyacrylic and methacrylates, polyvinyl aromatics, polyvinyl halides and a wide variety of copolymers, block and graft polymers, liquid crystal polymers or polymer mixtures.
Special representatives of these groups are polyethylene, polypropylene, polybutene, polypentene, polyvinyl chloride, polymethyl methacrylate, poly- (meth) acrylonitrile, possibly modified polystyrene, or multi-phase plastics such as ABS.
Polyaddition, polycondensation, polyoxidation or cyclization polymers are also suitable. Special representatives of these groups are polyamides, polyurethanes, polyureas, polyimides, polyesters, polyethers, polyhydantoins, polyphenylene oxide, polyphenylene sulfide, polysulfone polycarbonates, and their mixed forms, their mixtures and combinations with one another and with other polymers or polymer precursors, for example polyamide-6, polyamide -6.6, polyethylene terephthalate or bisphenol A polycarbonate.

The filaments (B) are preferably drawn polyester, polyamide or polyetherimide filaments.
Particularly preferred as filaments (B) are polyester POY filaments and in particular polyethylene terephthalate filaments.

It is particularly preferred that the filaments (B) are at the same time the thermoplastic filaments (matrix filaments) whose melting point is at least 10 ° C. below the melting point of the reinforcing filaments (A) of the hybrid yarn according to the invention.

In many cases it is desired that the three-dimensionally deformed thermoplastic molded articles produced from the hybrid yarns according to the invention via the sheet-like semifinished products should contain auxiliaries and additives such as fillers, stabilizers, matting agents or color pigments. In these cases, it is expedient that at least one of the filament types of the hybrid yarn additionally contains such auxiliaries and additives, in an amount of up to 40% by weight, preferably up to 20% by weight, in particular up to 12% by weight. % of the weight of the fiber components.
The proportion of thermoplastic fiber whose melting point is at least 10 ° C. lower than the melting point of the reinforcing filaments (A), ie the matrix fibers, contains the additional auxiliaries and additives in an amount of up to 40% by weight, preferably up to 20 % By weight, in particular up to 12% by weight, of the weight of the fiber components.
Preferred auxiliaries and additives which may be contained in the thermoplastic fiber content are fillers, stabilizers and / or pigments.

End products which are produced from the hybrid yarn according to the invention are the fiber-reinforced thermoplastic molded articles. These are made from the hybrid yarn using sheet-like, textile fabrics (semi-finished products) which, because the reinforcement filaments they contain are in a crimped state, are permanently three-dimensionally deformable.

The present invention also relates to these textile fabrics (semi-finished products) consisting of or containing a portion of the hybrid yarn according to the invention described above which significantly influences their deformability. The fabrics according to the invention can be woven fabrics, knitted fabrics or knitted fabrics, stabilized scrims or possibly bonded nonwoven fabrics.
The fabric is preferably a knitted or knitted fabric or a stabilized, unidirectional or multidirectional fabric, but in particular a fabric.

In principle, the woven surfaces can have all known fabric constructions such as the plain weave and its derivatives, such as rips, panama, Barley grain or mock leno weave, twill weave and its multiple derivatives, of which only herringbone twill, flat twill, braided twill, lattice twill, cross twill, pointed twill, zigzag twill, shadow twill or shadow cross twill are mentioned, or the satin weave with floats of different lengths. (Because of the bond designations see DIN 61101)
The density of each of the fabric surfaces is in the range of 2 to 60 threads / cm in warp and weft, depending on the application for which the material is intended and the titer of the yarns used in the production. Within this range, the densities of the fabric layers can be different or, preferably, the same.

In a further preferred embodiment of the textile materials according to the invention, the textile surfaces are knitted or knitted.
The knitted textile surfaces can be warp knitted or weft knitted, whereby the constructions can be varied widely by means of handles or floats. (See DIN 62050 and 62056)

A knitted or knitted textile material according to the invention can have right / right, left / left or a right / left stitch structure and their known variants as well as jacquard patterns.
The right / right stitch structure includes, for example, their variants clad, openwork, ribbed, offset, wave, catch or nub as well as the interlock binding right / right / crossed.
The left / left mesh structure also includes, for example, their variants clad, broken, interrupted, offset, translated, catch or pimple.
The right / left stitch structure also includes, for example, their variants plated, deposited, perforated, plush, lining, catch or pimple.

The woven or mesh weaves are selected according to the intended use of the textile material according to the invention, whereby purely technical expediency can be decisive, but occasionally also decorative aspects can be taken into account.

As already explained above, these flat structures according to the invention have very good permanent deformability, in particular deep-drawing ability, because the reinforcing filaments contained therein are in a crimped state.

The reinforcing filaments (A) of the hybrid yarn contained therein are preferably crimped by 5 to 60%, preferably 12 to 50%, in particular 18 to 36%.

The present invention also relates to fiber-reinforced molded parts consisting of 20 to 90, preferably 35 to 85, in particular 45 to 75% by weight of a sheet-like reinforcing material made from low-shrinking filaments (A) which is embedded in 10 to 80, preferably 15 up to 45, in particular 25 to 55% by weight of a thermoplastic matrix, 0 to 70, preferably 0 to 50, in particular 0 to 30% by weight of further fiber constituents and additionally up to 40% by weight, preferably up to 20% by weight %, in particular up to 12% by weight of the weight of the fiber and matrix components of auxiliaries and additives.

Sheet-like reinforcement materials which are embedded in the thermoplastic matrix can consist of sheets of parallel filaments which are arranged unidirectionally or e.g. are multidirectionally aligned and essentially stretched in superimposed layers. However, they can also consist of knitted or knitted fabrics, but preferably of woven fabrics.

Depending on the requirements of the application, the fiber-reinforced molded part according to the invention contains fillers, stabilizers and / or pigments as auxiliaries and additives.
A characteristic of these molded parts is that they are produced by deforming a fabric from the hybrid yarn described above, in which the reinforcing filaments are crimped, at a temperature which is above the melting point of the thermoplastic filaments and below the melting point of the reinforcing filaments (A).
It is important that they are produced by stretching deformation, the reinforcing filaments crimped in the semifinished product at least in the region of the deformed parts are stretched and pulled straight.

The melting point of the filaments used to produce the hybrid yarn according to the invention was determined in the differential scanning calorimeter (DSC) at a heating rate of 10 ° C./min.
To determine the dry heat shrinkage and the temperature of the maximum dry heat shrinkage of the filaments used, the filament was loaded with a tension of 0.0018 cN / dtex and the shrinkage temperature diagram was recorded. Both values can be taken from the curve shape obtained.
In order to determine the maximum shrinkage force, a shrinkage force-temperature curve was recorded continuously with a heating rate of 10 ° C./min and with an inlet and outlet velocity of the filament into and out of the oven. Both desired values can be taken from the curve.

The determination of the opening length as a measure of the degree of turbulence was carried out according to the principle of the hook drop test described in US-A-2985995 using an ITEMAT test device.

• die eingesetzten Filamente (A) der ersten Gruppe einen Anfangsmodul von über 600 cN/tex, vorzugsweise von 800 bis 25000 cN/tex, insbesondere von 2000 bis 20000 cN/tex,
  eine feinheitsbezogene Höchstzugkraft von über 60 cN/tex, vorzugsweise von 80 bis 220 cN/tex, insbesondere von 100 bis 200 cN/tex
  und eine Höchstzugkraftdehnung von 0,01 bis 20%, vorzugsweise von 0,1 bis 7,0 %, insbesondere von 1,0 bis 5,0 % haben
• die Filamente (B) der zweiten Gruppe Thermoplastfilamente sind, die einen Schmelzpunkt haben, der mindestens 10 °C, vorzugsweise 20 bis 100 °C, insbesondere 30 bis 70 °C unter dem Schmelzpunkt der Filamente (A) liegt.

Another object of this invention is a method for producing the hybrid yarn according to the invention, which is characterized in that a first group of filaments (filaments (A)) and a second group of filaments (filaments (B)) in a interlacing or blow texturing device, of which at least the filaments (A) are fed with an overfeed of 5 to 60% are swirled, whereby

• the filaments (A) of the first group used have an initial modulus of over 600 cN / tex, preferably from 800 to 25000 cN / tex, in particular from 2000 to 20,000 cN / tex,
  a fineness-related maximum tensile force of over 60 cN / tex, preferably from 80 to 220 cN / tex, in particular from 100 to 200 cN / tex
  and have a maximum tensile elongation of 0.01 to 20%, preferably 0.1 to 7.0%, in particular 1.0 to 5.0%
• the filaments (B) of the second group are thermoplastic filaments which have a melting point which is at least 10 ° C., preferably 20 to 100 ° C., in particular 30 to 70 ° C. below the melting point of the filaments (A).

In a variant, filaments (A) which have a crimp of 5% to 60%, preferably of 12 to 50%, in particular of 18 to 36%, with or without excess feed, or filaments (A) which have no crimp, are intermingled with the filaments (B) with an excess feed.

"Excess feed" of the filaments (A) means that the intermingling device is supplied with a greater length of filaments (A) than of filaments (B) in the unit time.

The swirling is preferably set so that the swirling degree of an opening length of less than 200 mm, preferably in the range from 5 to 100 mm, in particular in the range from 10 to 30 mm.

The process steps required to produce a fiber-reinforced thermoplastic molded article from the hybrid yarn according to the invention are also objects of the present invention.

The first of these steps is a method for producing a textile fabric (semi-finished product) by weaving, knitting, knitting, laying or tangling the hybrid yarn according to the invention, if appropriate together with other yarns, the hybrid yarn used according to the invention having the features described above and the proportion of the Hybrid yarn is chosen so that it significantly influences the permanent deformability of the fabric. Sufficient of the hybrid yarn according to the invention is preferably used here so that the proportion of the hybrid yarn in the total amount of the woven, knitted, knitted, laid or tangled yarn is 30 to 100% by weight, preferably 50 to 100% by weight, in particular 70 to 100% by weight .-%.

The fabric is preferably produced by weaving with a thread density of 4 to 20 threads / cm or by unidirectional or multidirectional laying of the hybrid yarns and stabilization of the scrim by cross-laid binding threads or by local or full-surface bonding.

It is particularly preferred and expedient that a hybrid yarn is used in which the degree of crimping of the filaments (A) is set so that it approximately corresponds to the elongation occurring during processing.

The last step in the processing of the hybrid yarn according to the invention is the production of a fiber-reinforced molded part consisting of 20 to 90, preferably 35 to 85, in particular 45 to 75% by weight of a sheet-like fiber material made of filaments (A), which is embedded in 10 to 80, preferably 15 to 45, in particular 25 to 55% by weight of a thermoplastic matrix, and 0 to 70, preferably 0 to 50, in particular 0 to 30% by weight of further fiber constituents and additionally up to 40% by weight, preferably up to up to 20% by weight, in particular up to 12% by weight, of the weight of the fiber and matrix constituents, auxiliaries and additives, by deforming a permanently deformable textile fabric according to the invention described above from hybrid yarn according to the invention at a temperature which is above the melting point the thermoplastic filaments (B) and below the melting point of the reinforcing filaments (A) is produced.

The following exemplary embodiments illustrate the production of the hybrid yarn according to the invention of the semifinished products I and II according to the invention and of a fiber-reinforced thermoplastic molded body according to the invention.

example 1

A multifilament glass yarn of 2 x 680 dtex and a multifilament yarn made of polyethylene terephthalate - yarn with a titer of 5 x dtex 300f64 (= 1500 dtex) are fed together to a swirling nozzle in which they are swirled by a stream of compressed air. The glass yarn is fed to the intermingling nozzle at a 25% faster rate than the polyethylene terephthalate yarn (25% excess feed).

The polyester yarn has a melting point of 250 ° C.
The swirled hybrid yarn obtained has a total titer of 3200 dtex, the opening length, measured with the ITEMAT device, is 19 mm.

Example 2

A textured multifilament high-modulus aramid yarn from dtex 220f200 dtex with a crimp of 35% and a multifilament yarn made from polyethylene terephthalate - yarn with a titer of 3x dtex 110f128 are fed together to a swirl nozzle, in which they are swirled by a stream of compressed air. The aramid yarn and the polyethylene terephthalate yarn are fed to the intermingling nozzle at approximately the same speed.
The polyester yarn has a melting point of 250 ° C.
The swirled hybrid yarn obtained has a total titer of 630 dtex, the opening length, measured with the ITEMAT device, is 21 mm.

Example 3

A fabric with a plain weave is made from the hybrid yarn produced according to Example 1.
The thread density in the warp is 7.4, in the weft 8.2 threads per cm.
This fabric (semi-finished product) has good permanent deformability. The possible increase in area when deforming is about 30%.
A fabric with practically the same properties can be obtained from the hybrid yarn produced according to Example 2.

Example 4

A semifinished product II produced according to Example 3 is drawn into a fender mold and heated to 280 ° C. for 3 minutes. After cooling to about 80 ° C., the raw molded fender body can be removed from the deep-drawing mold.
The fiber-reinforced thermoplastic molded body obtained has excellent strength. The reinforcement filaments are very evenly distributed and largely stretched.

The molded body is finished by trimming, smoothing and painting.

Claims (35)

Hybrid yarn consisting of two groups of filaments, one group consisting of one or more types of reinforcing filaments (filaments (A)) and the other group consisting of one or more types of matrix filaments (filaments (B)), characterized in that the filaments (A) of the first group have an initial modulus of over 600 cN / tex, preferably from 800 to 25000 cN / tex, in particular from 2000 to 20,000 cN / tex,
a fineness-related maximum tensile force of over 60 cN / tex, preferably from 80 to 220 cN / tex, in particular from 100 to 200 cN / tex
and have a maximum tensile elongation of 0.01 to 20%, preferably 0.1 to 7.0%, in particular 1.0 to 5.0% the filaments (B) of the second group are thermoplastic filaments which have a melting point which is at least 10 ° C., preferably 20 to 100 ° C., in particular 30 to 70 ° C. below the melting point of the filaments (A), - The filaments (A) have a crimp of 5% to 60%, preferably from 12 to 50%, in particular from 18 to 36%. Hybrid yarn according to claim 1, characterized in that the filaments of the hybrid yarn are interwoven. Hybrid yarn according to at least one of claims 1 and 2, characterized in that it has a total denier from 100 to 25000 dtex, preferably from 150 to 15000 dtex, in particular from 200 to 10000 dtex. Hybrid yarn according to at least one of Claims 1 to 3, characterized in that the proportion of filaments (A) is 20 to 90, preferably 35 to 85, in particular 45 to 75% by weight,
the proportion of filaments (B) 10 to 80, preferably 15 to 45, in particular 25 to 55% by weight and the proportion of further fiber components is 0 to 70, preferably 0 to 50, in particular 0 to 30% by weight of the hybrid yarn. Hybrid yarn according to at least one of Claims 1 to 4, characterized in that the filaments (A) have an initial modulus of over 600 cN / tex, preferably from 800 to 25000 cN / tex, in particular from 2000 to 20,000 cN / tex, a fineness-related maximum tensile force of over 60 cN / tex, preferably from 80 to 220 cN / tex, in particular from 100 to 200 cN / tex and a maximum tensile force elongation of 0.01 to 20%, preferably of 0.1 to 7.0%, in particular of 1.0 have up to 5.0%. Hybrid yarn according to at least one of claims 1 to 5, characterized in that the filaments (A) have a dry heat shrinkage maximum of less than 3%. Hybrid yarn according to at least one of claims 1 to 6, characterized in that the filaments (A) have individual titers of 0.1 to 20 dtex, preferably 0.4 to 16 dtex, in particular 0.8 to 10 dtex. Hybrid yarn according to at least one of claims 1 to 7, characterized in that the filaments (A) are inorganic filaments, filaments made of high-performance polymers or pre-shrunk and / or fixed organic filaments. Hybrid yarn according to at least one of claims 1 to 8, characterized in that the filaments (A) are metal, glass, ceramic or carbon filaments. Hybrid yarn according to at least one of Claims 1 to 9, characterized in that the filaments (A) are glass filaments. Hybrid yarn according to at least one of Claims 1 to 10, characterized in that the filaments (A) are pre-shrunk and / or fixed high-modulus aramid filaments or high-modulus polyester filaments. Hybrid yarn according to at least one of claims 1 to 11, characterized in that the filaments (B) are synthetic organic filaments. Hybrid yarn according to at least one of claims 1 to 12, characterized in that the filaments (B) are polyester, polyamide or polyetherimide filaments. Hybrid yarn according to at least one of Claims 1 to 13, characterized in that the filaments (B) are polyethylene terephthalate filaments. Hybrid yarn according to at least one of claims 1 to 14, characterized in that at least one of the filament types of the hybrid yarn additionally contains auxiliaries and additives, in an amount of up to 40% by weight, preferably up to 20% by weight, in particular up to to 12% by weight of the weight of the fiber components. Permanently deformable textile fabric consisting of or containing a portion of the hybrid yarn of claim 1 that significantly influences its deformability. Flat structure according to claim 16, characterized in that the flat structure is a woven fabric, knitted fabric or knitted fabric, a stabilized scrim or an optionally bonded non-woven fabric. Flat structure according to at least one of claims 16 and 17, characterized in that the flat structure is a woven fabric. Flat structure according to at least one of Claims 16 to 18, characterized in that it is a stabilized, unidirectional fabric. Flat structure according to at least one of claims 16 to 19, characterized in that the filaments (A) of the hybrid yarn contained therein are crimped by 5 to 60%, preferably 12 to 50%, in particular 18 to 36%. Fiber-reinforced molded part consisting of 20 to 90, preferably 35 to 85, in particular 45 to 75% by weight of a sheet-like fiber material made from low-shrinking filaments (A), which is embedded in 10 to 80, preferably 15 to 45, in particular 25 to 55% by weight of a thermoplastic matrix, 0 to 70, preferably 0 to 50, in particular 0 to 30% by weight of further fiber components and additionally up to 40% by weight, preferably up to 20% by weight, in particular up to 12 % By weight of the weight of the fiber and matrix components of auxiliaries and additives. Shaped part according to claim 21, characterized in that it contains fillers, stabilizers and / or pigments as auxiliaries and additives. Shaped part according to at least one of claims 21 and 22, characterized in that it is produced by deforming a textile fabric of claim 16 at a temperature which is above the melting point of the thermoplastic filaments and below the melting point of the reinforcing filaments (A). Shaped part according to at least one of claims 21 to 23, characterized in that it is produced by stretching deformation. A process for producing a hybrid yarn of claim 1, characterized in that a first group of filaments (filaments (A)) and a second group of filaments (filaments (B)) in a interlacing or Blast texturing device, to which at least the filaments (A) are fed with an overfeed of 5 to 60%, are swirled, whereby the filaments (A) used in the first group have an initial modulus of over 600 cN / tex, preferably from 800 to 25000 cN / tex, in particular from 2000 to 20,000 cN / tex,
a fineness-related maximum tensile force of over 60 cN / tex, preferably from 80 to 220 cN / tex, in particular from 100 to 200 cN / tex
and have a maximum tensile elongation of 0.01 to 20%, preferably 0.1 to 7.0%, in particular 1.0 to 5.0% - The filaments (B) of the second group are thermoplastic filaments which have a melting point which is at least 10 ° C., preferably 20 to 100 ° C., in particular 30 to 70 ° C. below the melting point of the filaments (A). A method according to claim 25, characterized in that the excess feeding of the filaments (A) is adjusted so that a crimp of 5% to 60%, preferably of 12 to 50%, in particular of 18 to 36%, is obtained in the interlaced hybrid yarn. Method according to at least one of claims 25 and 26, characterized in that the swirling is adjusted so that the swirling degree of an opening length, measured in the needle test, is <200 mm, preferably in the range from 5 to 100 mm, in particular in the range from 10 to Corresponds to 30 mm. A process for producing the textile fabric of claim 16 by weaving, knitting, knitting, laying or tangling a hybrid yarn, possibly together with other yarns, characterized in that the hybrid yarn used has the features mentioned in claim 1 and that the proportion of the hybrid yarn is chosen so is that it significantly influences the permanent deformability of the fabric, A method according to claim 28, characterized in that the proportion of the hybrid yarn in the total amount of the woven, entangled, knitted, laid or laid down yarn is 30 to 100 wt .-%, preferably 50 to 100 wt .-%, in particular 70 to 100 wt .-%. Method according to at least one of claims 28 and 29, characterized in that the fabric is produced by weaving with a thread density of 4 to 20 threads / cm. Method according to at least one of claims 28 to 30, characterized in that the fabric is produced by laying the yarns and stabilizing the scrim by means of cross-laid binding threads or by local or full-surface bonding. Process according to at least one of Claims 28 to 31, characterized in that a hybrid yarn is used in which the degree of crimping of the filaments (A) is set so that it approximately corresponds to the elongation which occurs during processing. A process for producing a fiber-reinforced molded part of claim 21, consisting of 20 to 90, preferably 35 to 85, in particular 45 to 75% by weight of a sheet-like fiber material made of filaments (A) which is embedded in 10 to 80, preferably 15 to 45, in particular 25 to 55% by weight of a thermoplastic matrix, and 0 to 70, preferably 0 to 50, in particular 0 to 30% by weight of further fiber constituents and additionally up to 40% by weight, preferably up to 20% by weight. %, in particular up to 12% by weight of the weight of the fiber and matrix constituents, auxiliaries and additives, characterized in that it is formed by deforming a textile fabric of claim 16 at a temperature which is above the melting point of the thermoplastic filaments and below the melting point of the Reinforcement filaments (A) is made. Use of a hybrid yarn of claim 1 for the manufacture of a permanently deformable fabric of claim 16. Use of the permanently deformable fabric of claim 16 for the production of a fiber-reinforced molded part of claim 21.