EP0737763B1 - 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. The invention further relates to the Deforming the deformable textile surfaces according to the invention fiber reinforced thermoplastic molded body, due to the unidirectional or multidirectional arranged, essentially stretched reinforcing filaments a targeted have 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 that have a high melting point or infusible filament content and a thermoplastic lower melting Have filament portion to produce fabrics that by heating over the Melting point of the thermoplastic, lower melting yarn component in fiber-reinforced, rigid thermoplastic sheets, so-called "organic sheets" are transferred can.

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 based on 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 reinforcing threads is usually negligible, textile surfaces made from conventional hybrid games 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 dispersant dissolved or dispersed matrix resin and to harden the resin by cooling or evaporating the solvent or dispersant.
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 at 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. Also This consists of a layer of longitudinal threads and a layer of transverse threads are not interwoven, but one of the thread layers is essential should have higher heat shrinkage than the other. With that from this Known material, the cohesion takes place through auxiliary threads that the Do not glue layers of the reinforcement threads together but against each other fix loosely to each other.

DE-A-40 serves to improve the deformability of reinforcing inserts 42 063 known method. This is used as textile reinforcement provided fabrics deformable in length, namely heat-shrinkable, Auxiliary threads incorporated. The shrink is triggered by heating and that Textile material contracted slightly so that the reinforcing threads are curled or in be held loosely.

DE-A-34 08 769 discloses a method for producing fiber-reinforced molded articles made of thermoplastic material, in which flexible textile Formations are used that are largely unidirectionally aligned Reinforcing fibers and one of thermoplastic yarns or fibers constructed matrix exist. These semi-finished products will be your final Shaped by heatable profile nozzles, practically all 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 the a plurality of spaced parallel reinforcing threads with very low elongation at break, which is embedded at regular intervals Have deflections that form a thread reservoir. When deforming this layered semi-finished products, the deflections of the reinforcing threads become straight pulled, which prevents tearing.

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 being deformed 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 are largely eliminated can overcome by a sheet-like semi-finished product that has a textile character, permanently deformable, e.g. deep-drawable, and is both the reinforcing fibers and also contains the matrix material in a defined weight ratio.

Such an advantageous semi-finished product can be woven, knitted or knitted, however also by cross-laying or other known manufacturing processes sheet-like textiles are produced 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 are included in the terms "Fibers", "Fiber Materials", "Fiber Components" and with these terms compound terms also "filaments", "filament materials", To understand filament components "and related terms "Fiber or filament components" are not the chemical components of the To understand fibers or filaments, but the fibrous or filament-shaped Components of the hybrid yarns, semi-finished products and fiber reinforced according to the invention thermoplastic molded body.

• 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 processed more easily into flat structures on conventional machines, for example woven, knitted or knitted, and that in the production of fiber-reinforced thermoplastic molded articles from the sheet-like textile material because of the intimate mixture of the reinforcement and the Matrix fibers, very short flow paths of the melted matrix material and an excellent, seamless 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 sequence of small or larger sheets. "Ripple" in the sense of this invention is the undrawn, undulating course of the filaments (A) in the hybrid yarn understand, which is brought about by the fact that the length of the filaments (A) is greater is than the length of yarn in which they are contained.

The hybrid yarn according to the invention expediently has a total titer of 100 up to 25,000 dtex, preferably from 150 to 15,000 dtex, in particular from 200 to 10000 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) whose melting point is at least 10 ° C lower is the melting point of the reinforcing fibers (A), is 10 to 80, preferably 15 to 45, in particular 20 to 40 wt .-% of the invention Hybrid yarn.

Advantageously, the filaments (A) which form the reinforcement filaments in the end product, ie the fiber-reinforced three-dimensional thermoplastic molded body, 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 from other suitable for the production of high-strength filaments organic polymers.

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, especially from 0.25 to 1.5 dtex.

Filaments made of high-performance polymers in the sense of this invention are filaments made of Polymers that have little or no stretching, possibly after one Spinning process downstream heat treatment, filaments with very high Initial module and very high tensile strength (= fineness-related maximum tensile force) deliver. 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 imides) (PAI), Polybenzimidazole (PBI), poly (p-phenylene benzobisoxazole) (PBO), poly (p-phenylene benzobistiazole) (PBT), Polyether ketone (PEK), polyether ether ketone (PEEK), Polyether ether ketone ketone (PEEKK), polyether imides (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.

As far as the filaments (A) are the required ones mentioned above Melting point difference of at least 10 ° C, preferably 20 to 100 ° C. in particular 30 to 70 ° C, they can have from the above High performance polymers exist. Filaments (B) made of polyetherimide are an example (PEI) 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) simultaneously Thermoplastic filaments (matrix filaments) have a melting point of at least 10 ° C below the melting point of the reinforcing filaments (A) of the invention Hybrid yarn lies.

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 that are made from the hybrid yarn of the invention are fiber-reinforced thermoplastic molded body. These are made from the hybrid yarn sheet-like, textile fabric (semi-finished product), which, because the in it reinforcement filaments contained are present in a crimped state, are permanently deformable in three dimensions.

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, for example, grosgrain, panama, barley grain or mock leno weave, the twill weave and its multiple derivatives, of which only, for example, herringbone twill, flat twill, braided twill, grid twill, cross twill , Pointed twill, zigzag twill, shadow twill or shadow cross twill, or the satin weave with floats of various 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 weave or stitch bindings are made according to the intended purpose of the textile material according to the invention selected, being purely technical Functionality is crucial, but occasionally also decorative Aspects can be taken into account.

As already explained above, these fabrics according to the invention have a very good permanent deformability, especially deep drawing ability, because the reinforcement filaments contained therein are present in a crimped state.

The reinforcing filaments (A) of the hybrid yarn contained therein are preferably curled 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, a sheet-like reinforcement material made of 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 wt .-%, in particular up to 12 wt .-% of the weight of the fiber and Matrix components auxiliary and additives.

Flat reinforcement materials embedded in the thermoplastic matrix, can consist of sets of parallel filaments, which are arranged unidirectionally or e.g. multidirectionally aligned in superimposed layers and in are substantially stretched. But you can also knit or knit from fabrics Knitted, but preferably made of 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 being stretched and drawn at least in the region of the deformed parts.

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 swirl 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 one variant, filaments (A) which have a crimp of 5% to 60%, preferably from 12 to 50%, especially from 18 to 36%, with or without Excess feed, or filaments (A), which have no crimp, with a Excess feed are swirled with the filaments (B).

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

The swirl is preferably adjusted so that the degree of swirl is one Opening length, of less than 200 mm, preferably in the range of 5 to 100 mm, is in particular in the range from 10 to 30 mm.

The process steps that are required to get from the invention Hybrid yarn to produce a fiber-reinforced thermoplastic molded body Objects of the present invention.

The first of these steps is a process for making a textile Fabric (semi-finished product) by weaving, knitting, knitting, laying or Tangled deposit of the hybrid yarn according to the invention, possibly together with other yarns, the hybrid yarn according to the invention used being those described above Features and wherein the proportion of the hybrid yarn is chosen so that it permanent deformability of the fabric significantly influenced. Preferably so much of the hybrid yarn according to the invention is used that the proportion of Hybrid yarn on the total amount of the woven, knitted, forged, laid or tangled yarn 30 to 100 wt .-%, preferably 50 to 100 wt .-%, is in particular 70 to 100% by weight.

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

It is particularly preferred and expedient that a hybrid yarn is used for which the degree of crimping of the filaments (A) is set so that it is about the elongation during processing.

The last step in the processing of the hybrid yarn according to the invention consists in Production of a fiber-reinforced molded part consisting of 20 to 90, preferably 35 to 85, in particular 45 to 75 wt .-%, of a sheet-like fiber material 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 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 constituents auxiliary and additives, by deformation of a permanently deformable textile according to the invention described above Sheet made of hybrid yarn according to the invention at a temperature which above the melting point of the thermoplastic filaments (B) and below the melting point the reinforcing filaments (A) is produced.

The following embodiments illustrate the manufacture of the Hybrid yarn according to the invention of the semifinished products I and II and one Fiber-reinforced thermoplastic molded body according to the invention.

example 1

A multifilament glass yarn of 2 x 680 dtex and a multifilament yarn Polyethylene terephthalate yarn with a titer of 5 x dtex 300f64 (= 1500 dtex) jointly fed to a swirl nozzle, in which they flow through a stream of compressed air to be swirled. The glass yarn of the interlacing nozzle is fed faster than the polyethylene terephthalate yarn (25% Excess supply).

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 (33)

1. A hybrid yarn consisting of two groups of filaments, one group consisting of one or a plurality of types of reinforcing filaments (filaments (A)) while the other group consists of one or a plurality of types of matrix filaments (filaments (B)), characterised in that filaments (A) of the first group have an initial modulus of over 600 cN/tex, preferably of 800 to 25,000 cN/tex, in particular from 2,000 to 20,000 cN/tex,

   a fineness-related maximum tensile strength of over 60 cN/tex, preferably from 80 to 220 cN/tex and in particular from 100 to 200 cN/tex
   and a maximum stress-strain level of 0.01 to 20%, preferably from 0.1 to 7.0% and particularly from 1.0 to 5.0%,

   the filaments (B) of the second group are thermoplastic filaments which have a melting point at least 10°C and preferably 20 to 100°C and particularly 30 to 70°C below the melting point of filaments (A),

   filaments (A) have a curl-in of 5% to 60%, preferably 12 to 50% and particularly of 18 to 36%.
2. A hybrid yarn according to claim 1, characterised in that the filaments of the hybrid yarn are swirled with one another.
3. A hybrid yarn according to at least one of claims 1 and 2, characterised in that it has a total titre of 100 to 25,000 dtex, preferably 150 to 15,000 dtex and particularly 200 to 10,000 dtex.
4. A hybrid yarn according to at least one of claims 1 to 3, characterised in that the proportion of filaments (A) is 20 to 90, preferably 35 to 85 and particularly 45 to 75% by weight,
   the proportion of filaments (B) is 10 to 80, preferably 15 to 45 and particularly 25 to 55% by weight and the proportion of further fibre constituents is 0 to 70, preferably 0 to 50 and particularly 0 to 30% by weight of the hybrid yarn.
5. A hybrid yarn according to at least one of claims 1 to 4, characterised in that filaments (A) have an initial modulus of over 600 cN/tex, preferably 800 to 25,000 cN/tex and particularly 2,000 to 20,000 cN/tex, a fineness-related maximum tensile strength of over 60 cN/tex, preferably 80 to 220 cN/tex, particularly 100 to 200 cN/tex and a maximum stress-strain level of 0.01 to 20%, preferably 0.1 to 7.0% and particularly 1.0 to 5.0%.
6. A hybrid yarn according to at least one of claims 1 to 5, characterised in that filaments (A) have a dry heat-shrinkage maximum of less than 3%.
7. A hybrid yarn according to at least one of claims 1 to 6, characterised in that filaments (A) have an individual titre of 0.1 to 20 dtex preferably 0.4 to 16 dtex and particularly 0.8 to 10 dtex.
8. A hybrid yarn according to at least one of claims 1 to 7, characterised in that filaments (A) are inorganic filaments, filaments of heavy duty polymers or pre-shrunk and/or fixed organic filaments.
9. A hybrid yarn according to at least one of claims 1 to 8, characterised in that filaments (A) are metallic, glass, ceramic or carbon filaments.
10. A hybrid yarn according to at least one of claims 1 to 9, characterised in that filaments (A) are glass filaments.
11. A hybrid yarn according to at least one of claims 1 to 10, characterised in that filaments (A) are pre-shrunk and/or fixed high modulus aramide filaments or high modulus polyester filaments
12. A hybrid yarn according to at least one of claims 1 to 11, characterised in that filaments (B) are synthetic organic filaments.
13. A hybrid yarn according to at least one of claims 1 to 12, characterised in that filaments (B) are polyester, polyamide or polyether imide filaments.
14. A hybrid yarn according to at least one of claims 1 to 13, characterised in that filaments (B) are polyethylene terephthalate filaments.
15. A hybrid yarn according to at least one of claims 1 to 14, characterised in that at least one of the filament types in the hybrid yarn additionally contains adjuvants and additives, in an amount of up to 40% by weight, preferably up to 20% by weight and particularly up to 12% by weight of the weight of the fibre constituents.
16. A permanently deformable flat textile structure consisting of or containing a proportion of the hybrid yarn of claim 1 which can significantly influence its workability.
17. A flat structure according to claim 16, characterised in that the flat structure is a woven or knitted fabric, a stabilised laid fabric or a possibly bonded tangled fleece.
18. A flat structure according to at least one of claims 16 and 17, characterised in that the flat structure is a woven fabric.
19. A flat structure according to at least one of claims 16 to 18, characterised in that it is a stabilised and uni-directional laid structure.
20. A flat structure according to at least one of claims 16 to 19, characterised in that filaments (A) of the hybrid yarn contained therein are curled in by 5 to 60%, preferably 12 to 50% and particularly 18 to 36%.
21. A fibre reinforced moulding, characterised in that it is produced by shaping a flat textile structure according to 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).
22. A moulding according to claim 21, consisting of 20 to 90, preferably 35 to 85 and particularly 45 to 75% by weight of a flat-shaped fibre material of minimally shrinking filaments (A), which is embedded in 10 to 80, preferably 15 to 45 and particularly 25 to 55% by weight of a thermoplastic matrix, 0 to 70, preferably 0 to 50 and particularly 0 to 30% by weight of further fibre constituents and additionally up to 40% by weight, preferably up to 20% by weight and particularly up to 12% by weight of the weight of the fibre and matrix constituents adjuvants and additives.
23. A moulding according to claim 22, characterised in that as adjuvants and additives it contains, fillers, stabilisers and/or pigments.
24. A moulding according to at least one of claims 21 to 232, characterised in that it is produced by a stretching type of deformation.
25. A method of producing the hybrid yarn of claim 1, characterised in that a first group of filaments (filaments (A)) and a second group of filaments (filaments (B)) are swirled in a swirling or glowing-texturing arrangement to which at least filaments (A) are fed with an overfeed of 5 to 60%,

    the filaments (A) of the first group which are used having an initial modulus of over 600 cN/tex, preferably 800 to 25,000 cN/tex and particularly 2,000 to 20,000 cN/tex,

    a fineness related maximum tensile strength of over 60 cN/tex, preferably 80 to 220 cN/tex and particularly 100 to 200 cN/tex
    and a maximum stress-strain level of 0.01 to 20%, preferably 0.1 to 7% and particularly 1 to 5%,

    filaments (B) of the second group are thermoplastic filaments having a melting point which is at least 10°C, preferably 20 to 100°C and particularly 30 to 70°C below the melting point of the filaments (A).
26. A method according to claim 25, characterised in that the overfeed of filaments (A) is so adjusted that a curl-in of 5% to 60%, preferably 12 to 50% and particularly 18 to 36% is adjusted in the swirled hybrid yarn.
27. A method according to at least one of claims 25 and 26, characterised in that the turbulence is so adjusted that the degree of turbulence corresponds to an opening length, measured in the needle test, of <200 mm, preferably in the range from 5 to 100 mm and particularly in the range from 10 to 30 mm.
28. A method of producing the flat textile structure according to claim 16 by weaving, knitting, laying or the tangled deposition of a hybrid yarn, possibly together with other yarns, characterised in that the hybrid yarn used has the features disclosed in claim 1 and in that the proportion of the hybrid yarn is so chosen that it significantly influences the permanent workability of the flat structure.
29. A method according to claim 28, characterised in that the proportion of the hybrid yarn in the total amount of the woven, knitted, worked, laid or tangled yarn amounts to 30 to 100% by weight and preferably 50 to 100% by weight and particularly 70 to 100% by weight.
30. A method according to at least one of claims 28 and 29, characterised in that the flat structure is produced by weaving with a thread density of 40 to 20 threads per cm.
31. A method according to at least one of claims 28 to 30, characterised in that the flat structure is produced by laying the yarns and stabilising the laid structure by transversely laid bonding threads or by localised or all-over bonding.
32. A method according to at least one of claims 28 to 31, characterised in that a hybrid yarn is used in which the degree of curl-in of the filaments (A) is so adjusted that it corresponds substantially to the elongation which occurs during working.
33. A method of producing a fibre-reinforced moulding according to claim 21, consisting of 20 to 90, preferably 35 to 85 and particularly 45 to 75% by weight of a flat-shaped fibre material consisting of filaments (A), which is embedded in 10 to 80, preferably 15 to 45 and particularly 25 to 55% by weight of a thermoplastics matrix as well as 0 to 70, preferably 0 to 50 and particularly 0 to 30% by weight of further fibre constituents and additionally up to 40% by weight, preferably up to 20% by weight and particularly up to 12% by weight of the weight of the fibre and matrix constituents adjuvants and additives, characterised in that it is produced by shaping a flat textile structure according to 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).