EP2812184A1 - Sheetlike composite material - Google Patents

Sheetlike composite material

Info

Publication number
EP2812184A1
EP2812184A1 EP13707292.2A EP13707292A EP2812184A1 EP 2812184 A1 EP2812184 A1 EP 2812184A1 EP 13707292 A EP13707292 A EP 13707292A EP 2812184 A1 EP2812184 A1 EP 2812184A1
Authority
EP
European Patent Office
Prior art keywords
composite material
material according
layers
layer
fibers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP13707292.2A
Other languages
German (de)
French (fr)
Inventor
Burak Baser
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Quadrant Plastic Composites AG
Original Assignee
Quadrant Plastic Composites AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Quadrant Plastic Composites AG filed Critical Quadrant Plastic Composites AG
Priority to EP13707292.2A priority Critical patent/EP2812184A1/en
Publication of EP2812184A1 publication Critical patent/EP2812184A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/14—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of indefinite length
    • B29C39/20—Making multilayered or multicoloured articles
    • B29C39/203—Making multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/30—Making multilayered or multicoloured articles
    • B29C43/305—Making multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
    • B29C51/145—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets having at least one layer of textile or fibrous material combined with at least one plastics layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/504—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands
    • B29C70/506—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands and impregnating by melting a solid material, e.g. sheet, powder, fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • B32B27/285—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyethers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • B32B27/288—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyketones
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/10—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer reinforced with filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/04—4 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/05—5 or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/08—Reinforcements
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1043—Subsequent to assembly
    • Y10T156/1044—Subsequent to assembly of parallel stacked sheets only
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
    • Y10T428/24074—Strand or strand-portions
    • Y10T428/24091—Strand or strand-portions with additional layer[s]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24132—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in different layers or components parallel

Abstract

The invention relates to a sheetlike composite material comprising at least one layer A of a nonwoven thermoplastic fibre web or a thermoplastic film, and at least two unidirectional oriented-fibre layers B and B', the layers B and B' having a bidirectional fibre orientation. The layers are not only needled but also stitched to one another.

Description

Flächiger Verbundwerkstoff  Flat composite material
Die Erfindung betrifft einen flächigen Verbundwerkstoff gemäss Oberbegriff des Anspruchs 1 sowie ein Verfahren zu dessen Herstellung und eine Verwendung desselben. The invention relates to a sheet-like composite material according to the preamble of claim 1 and a method for its production and a use thereof.
Thermoplastische Kunststoffe werden wegen ihres geringen Gewichts in zunehmendem Masse zur Herstellung von Formteilen, insbesondere von Bauteilen für Kraftfahrzeuge verwendet. Um ihnen eine ausreichende Festigkeit und Steifigkeit zu verleihen, werden sie gewöhnlich mit Verstärkungsfasern verbunden. So werden zum Beispiel flächige Halbzeuge aus glasmattenverstärkten Thermoplasten hergestellt durch Zusammenführen von Endlos-Glasfasermatten mit Wirrfasern und Thermoplast-Schmelzebahnen und Konsolidieren auf einer Doppelbandpresse. Aus dem erhaltenen flächigen Halbzeug können durch Heissverpressen in einer Form Bauteile hergestellt werden. Dabei ist jedoch die Faserverstärkung ungerichtet, d.h., sie wirkt gleichmässig in allen Richtungen ohne Vorzugsrichtung, so dass die Festigkeit solcher Verbünde limitiert ist. In vielen Fällen benötigt man jedoch Bauteile, die in Vorzugsrichtungen verstärkt sind. Dies kann man dadurch erreichen, dass als Verstärkungsfasern Fasergewebe oder Fasergelege aus parallelen Faserbündeln (Rovings) verwendet werden. So ist beispielsweise in der WO 2006/1 1 1037 ein flächiger Verbundwerkstoff beschrieben, der eine Faservlies-Schicht aus Thermoplastfasern und eine Gewebe- oder Gelege- Schicht aus parallelen Verstärkungsfaserbündeln enthält. Die einzelnen Schichten können entweder zusammengenadelt, zusammengenäht oder thermisch miteinander verbunden werden. Dieser Verbundwerkstoff kann durch Heissverpressen zu Bauteilen mit gezielter Verstärkung verarbeitet werden. Thermoplastics are used because of their low weight increasingly for the production of moldings, in particular of components for motor vehicles. To give them sufficient strength and rigidity, they are usually bonded with reinforcing fibers. For example, flat semi-finished products made of glass mat-reinforced thermoplastics are produced by combining endless glass fiber mats with random fibers and thermoplastic melt webs and consolidating on a double belt press. From the flat semi-finished product obtained can be produced by hot pressing in a mold components. However, the fiber reinforcement is undirected, that is, it acts uniformly in all directions without preferential direction, so that the strength of such composites is limited. In many cases, however, you need components that are reinforced in preferred directions. This can be achieved by using fiber fabrics or fiber scrims made of parallel fiber bundles (rovings) as reinforcing fibers. Thus, for example, in WO 2006/1 1 1037 a planar composite material is described which contains a nonwoven layer of thermoplastic fibers and a fabric or scrim layer of parallel reinforcing fiber bundles. The individual layers can either be stitched together, sewn together or thermally bonded together. This composite material can be processed by hot pressing into components with targeted reinforcement.
Beim Nadeln werden die Faserbündel geöffnet und die Fasern werden teilweise gebrochen. Dabei werden aber die Einzelfasern etwas gegeneinander verscho- ben, so dass die Orientierung teilweise aufgehoben und die Verstärkungswirkung vermindert wird. Beim Vernähen werden die einzelnen Faserbündel durch Bindefäden miteinander und mit den Fasern der Vliesschicht verbunden. Dabei werden aber die Faserbündel nicht geöffnet, so dass die Thermoplast-Schmelze die Gewebe- bzw. Gelege-Schicht nur unvollständig tränken kann, was zu geringerer Tragfähigkeit daraus hergestellter Bauteile führt. When needling, the fiber bundles are opened and the fibers are partially broken. In the process, however, the individual fibers are displaced slightly relative to one another, so that the orientation is partially canceled and the reinforcing effect is reduced. When sewing the individual fiber bundles through Binding threads connected to each other and to the fibers of the nonwoven layer. In this case, however, the fiber bundles are not opened, so that the thermoplastic melt can impregnate the fabric or scrim layer only incompletely, which leads to lower carrying capacity of components produced therefrom.
Der Erfindung lag daher die Aufgabe zugrunde, mit Fasergelegen verstärkte Verbundwerkstoffe bereitzustellen, die die jeweiligen genannten Nachteile nicht aufweisen. Eine weitere Aufgabe bestand darin, flächige Verbundwerkstoffe bereitzustellen, die eine Verstärkung in mehreren Richtungen aufweisen, aus de- nen Bauteile mit einer bidirektionalen Verstärkung hergestellt werden können. The invention therefore an object of the invention to provide fiber reinforced reinforced composite materials that do not have the respective disadvantages mentioned. Another object was to provide sheet composites that have multi-directional reinforcement from which components with bidirectional reinforcement can be made.
Letzteres wird im Prinzip auch mit den Verbundwerkstoffen nach WO 2006/1 1 1307 erreicht, wenn zur Verstärkung ein Fasergewebe eingesetzt wird. Bei Geweben sind jedoch die Faserbündel an den Kreuzungspunkten onduliert, was zu einer Verminderung der Druckfestigkeit in Faserrichtung führt. Ausserdem befindet sich an den Kreuzungspunkten zwischen den Faserbündeln kein Thermoplast. Diese Trockenstellen haben eine ungleichmässige Tränkung zur Folge. Auch diese Nachteile sollten durch die vorliegende Erfindung vermieden werden. The latter is in principle also achieved with the composites according to WO 2006/1 1 1307, if a fiber fabric is used for reinforcement. In the case of fabrics, however, the fiber bundles are undulated at the points of intersection, which leads to a reduction in the compressive strength in the fiber direction. In addition, there is no thermoplastic at the crossing points between the fiber bundles. These dry spots result in uneven impregnation. These disadvantages should also be avoided by the present invention.
Weitere Arten von flächigen Verbundwerkstoffen sind in EP 0 203 803 A1 und US 3,761 ,345 A beschrieben. Further types of laminar composites are described in EP 0 203 803 A1 and US Pat. No. 3,761,345 A.
Die EP 0 203 803 A1 betrifft eine verstärkte Harzmasse, die Lagen aus paral- lelen Verstärkungsfasern und Pufferlagen aus Aramidfasern enthält. Das Fasergebilde ist in einem gehärteten Harz eingelagert. Aramidfasern sind Hoch- leistungsverstärkungsfasern aus einem aromatischen Polyamid, die im Gegensatz zu aliphatischen Polyamiden nicht schmelzbar und deshalb auch nicht thermoplastisch verarbeitbar sind. Die US 3,761 ,345 A beschreibt ein Fasergebilde, das ein Harz absorbieren kann. Daraus können durch Härten des Harzes glasfaserverstärkte Harzartikel hergestellt werden. Das Fasergebilde besteht aus einer Vielzahl von Schichten. In diesen können die Fasern entweder unidirektional oder in Form von Schlaufen vorliegen; ferner kann die mittlere Schicht auch aus wirren Bündeln von kurzen Schnittfasern bestehen. Faservlies-Schichten, in denen die Fasern zumindest teilweise aus einem Thermoplasten bestehen, sind in der US 3,761 ,345 A nicht geoffenbart, darüber hinaus ist die Herstellung von Bauteilen oder Halbzeugen durch thermoplastisches Heissverpressen der Verbundwerkstoffe nicht beschrieben. EP 0 203 803 A1 relates to a reinforced resin composition which contains layers of parallel reinforcing fibers and buffer layers of aramid fibers. The fiber structure is embedded in a hardened resin. Aramid fibers are high-performance reinforcing fibers made of an aromatic polyamide, which, in contrast to aliphatic polyamides, are not meltable and therefore can not be processed thermoplastically. US 3,761,345 A describes a fibrous structure which can absorb a resin. This can be made by curing the resin glass fiber reinforced resin article. The fiber structure consists of a plurality of layers. In these, the fibers may be either unidirectional or in the form of loops; furthermore, the middle layer can also consist of tangled bundles of short cut fibers. Non-woven fabric layers in which the fibers at least partially consist of a thermoplastic are not disclosed in US Pat. No. 3,761,345 A, moreover the production of components or semi-finished products by thermoplastic hot-pressing of the composite materials is not described.
Gegenstand der Erfindung ist somit ein flächiger Verbundwerkstoff, umfassend mindestens eine Schicht A aus einem Faservlies, bestehend aus 40 bis 100 Gew.-% Thermoplastfasern und 60 bis 0 Gew.-% Verstärkungsfasern, oder einer Thermoplastfolie, sowie The invention thus relates to a planar composite material, comprising at least one layer A of a nonwoven fabric consisting of 40 to 100 wt .-% thermoplastic fibers and 60 to 0 wt .-% reinforcing fibers, or a thermoplastic film, and
mindestens zwei unidirektionalen Fasergelege-Schichten B und B' aus parallelen Verstärkungsfaserbündeln, wobei die Schichten B und B' eine bidirektionale Faserorientierung aufweisen.  at least two unidirectional fiber ply layers B and B 'of parallel reinforcing fiber bundles, said layers B and B' having bidirectional fiber orientation.
Erfindungsgemäss sind beim Verbundwerkstoff die Schichten sowohl miteinan- der vernäht als auch genadelt. According to the invention, in the case of the composite material, the layers are sewn together as well as needled.
Der Begriff "Thermoplast" ist wie im Fachgebiet allgemein bekannt dahingehend zu verstehen, dass die betreffenden Materialien unter herkömmlichen Verarbeitungsbedingungen aufschmelzbar und thermoplastisch verformbar sind. As is well known in the art, the term "thermoplastic" is to be understood to mean that the respective materials are meltable and thermoplastically deformable under conventional processing conditions.
Gemäss einer vorteilhaften Ausgestaltung enthält das Faservlies der Schicht A bis zu 50 Gew.-% Verstärkungsfasern. Gemäss einer anderen vorteilhaften Ausgestaltung enthält das Faservlies der Schicht A gar keine Verstärkungsfasern und ist demnach allein aus Thermoplastfasern gebildet. Gemäss einer weiteren vorteilhaften Ausgestaltung ist die Schicht A aus einer Thermoplastfolie gebildet. "Bidirektional" bedeutet im Zusammenhang mit zwei Fasergelegen B und B', dass die Längsachse des Fasergeleges B nicht parallel zu der Längsachse des Fasergeleges B' ist. Ein weiterer Gegenstand der Erfindung sind Verfahren zur Herstellung derartiger Verbundwerkstoffe. Dabei gibt es zwei Varianten: According to an advantageous embodiment, the nonwoven fabric of the layer A contains up to 50 wt .-% reinforcing fibers. According to another advantageous embodiment, the nonwoven fabric of the layer A contains no reinforcing fibers and is accordingly formed solely from thermoplastic fibers. According to a further advantageous embodiment, the layer A is formed from a thermoplastic film. "Bidirectional" in the context of two fiber webs B and B 'means that the longitudinal axis of the fiber web B is not parallel to the longitudinal axis of the fiber web B'. Another object of the invention are methods for producing such composite materials. There are two variants:
Bei der ersten Variante werden zunächst die Faservlies-Schicht(en) A nach dem Krempel-, Airlay- oder Spinnvlies-Verfahren oder aber nach dem sogenannten Papiermacherverfahren hergestellt, dann werden die bidirektional zueinander ausgerichteten Gelege-Schichten B und B' mit der bzw. den Schicht(en) A kontinuierlich zusammengeführt. Die Schichten werden dann miteinander vernäht und anschliessend genadelt. Bei der zweiten Variante werden die Thermoplastfolie(n) der Schicht A und die bidirektional zueinander ausgerichteten Fasergelege der Schichten B und B' kontinuierlich zusammengeführt, miteinander vernäht und anschliessend genadelt. In the first variant, first the nonwoven layer (s) A are produced according to the carding, Airlay or spunbonding method or else according to the so-called papermaking method, then the bidirectionally aligned scrim layers B and B 'are produced with the or the layer (s) A continuously merged. The layers are then sewn together and then needled. In the second variant, the thermoplastic film (s) of the layer A and the bidirectionally aligned fiber layers of the layers B and B 'are continuously brought together, sewn together and then needled.
Bevorzugte Schichtanordnungen sind B - A - B' und B - A - B' - A - B. Weitere Anordnungen mit mehreren, bis zu 20 Schichten sind möglich. Es ist bevorzugt, dass immer eine Faservlies- bzw. Thermoplastfolien-Schicht A zwischen zwei Gelege-Schichten B bzw. B' angeordnet ist. Für spezielle Anwendungen ist auch eine Anordnung, bei der eine Schicht A aussen liegt, möglich. Die Faserorientierung der Schichten B bzw. B' ist bidirektional, bevorzugte Orientierungen sind 0 90°, 30 -30°, 457 -45° und 607 -60° gegenüber einer Referenzrichtung in der Schichtanordnung wie beispielsweise deren Längsachse L. Dementsprechend beträgt der spitze Zwischenwinkel zwischen den jeweiligen Faserrichtungen vorzugsweise 60° oder 90°. Die Schichtenlagen sind dabei vor- zugsweise symmetrisch anzuordnen. Die Figur 1 zeigt in perspektivischer Ansicht eine Schichtanordnung B - A - B' mit einer bidirektionalen Faserorientierung 457 -45° der Schichten B bzw. B' gegenüber einer Längsachse L. Die Flächengewichte der einzelnen Schichten liegen vorzugsweise zwischen 20 bis 1 Ό00 g/m2, insbesondere 30 bis 1 Ό00 g/m2, ganz besonders zwischen 150 und 300 g/m2. Die einzelnen Gelege-Schichten können auch unterschiedliche Flächengewichte aufweisen. Die Flächengewichte sind so auszuwählen, dass der Anteil der gesamten Verstärkungsfasern im Verbundwerkstoff vorzugsweise 20 bis 80 Gew.-%, insbesondere 30 bis 70 Gew.-% und besonders bevorzugt etwa 60 Gew.-% beträgt. Preferred layer arrangements are B - A - B 'and B - A - B' - A - B. Further arrangements with several, up to 20 layers are possible. It is preferred that always a nonwoven or thermoplastic film layer A is disposed between two scrim layers B and B '. For special applications, an arrangement in which a layer A is outside is possible. The fiber orientation of the layers B and B 'is bidirectional, preferred orientations are 0 90 °, 30 -30 °, 457-45 ° and 607-60 ° with respect to a reference direction in the layer arrangement such as the longitudinal axis L. Accordingly, the acute inter-angle is between the respective fiber directions preferably 60 ° or 90 °. The layer layers are preferably to be arranged symmetrically. FIG. 1 shows a perspective view of a layer arrangement B - A - B 'with a bidirectional fiber orientation 457 - 45 ° of the layers B and B' relative to a longitudinal axis L. The basis weights of the individual layers are preferably between 20 and 1 Ό00 g / m 2 , in particular 30 to 1 Ό00 g / m 2 , especially between 150 and 300 g / m 2 . The individual scrim layers can also have different basis weights. The basis weights are to be selected so that the proportion of the total reinforcing fibers in the composite material is preferably 20 to 80 wt .-%, in particular 30 to 70 wt .-% and particularly preferably about 60 wt .-%.
Bevorzugte Verstärkungsfasern sind Glasfasern und Kohlenstofffasern, daneben sind auch Aramidfasern, Basaltfasern, Naturfasern, und Fasern aus höher schmelzenden Polymeren sowie Hybridfasern, z.B. aus Glasfasern und Polypropylenfasern geeignet. Vorzugsweise sind die Faserarten in den einzelnen Schichten jeweils gleich. Die Verstärkungsfasern des Geleges liegen vorzugsweise als Faserbündel mit einem Titer zwischen 300 und 4'800 tex vor. Bevorzugte Thermoplasten in dem Faservlies bzw. in der Thermoplastfolie sind Polypropylen und schmelzbare Polyamide, namentlich aliphatische Polyamide; daneben sind auch andere Thermoplasten, wie Polyester, Polyethersulfon, Po- lyetherketone und Polyetherimid geeignet. Polyetherketone zeichnen sich insbesondere durch eine gute Temperaturbeständigkeit aus. Verbundwerkstoffe mit besonders guter Fliessfähigkeit werden erhalten, wenn der Thermoplast Polypropylen mit einem Schmelzflussindex (melt flow index, MFI) (230°C, 2.16 kg) zwischen 10 und 400, insbesondere bei etwa 120 g/10 min ist. Die Thermoplaste zur Herstellung des Faservlieses der Schicht A können in sehr unterschiedlichen Abmessungen und Geometrien bereitgestellt werden. Die einzelnen Schichten des Verbundwerkstoffs sind sowohl miteinander vernäht als auch genadelt. Preferred reinforcing fibers are glass fibers and carbon fibers, besides aramid fibers, basalt fibers, natural fibers, and fibers of higher melting polymers and hybrid fibers, such as glass fibers and polypropylene fibers are suitable. Preferably, the types of fibers in each layer are the same. The reinforcing fibers of the fabric are preferably present as fiber bundles with a titer between 300 and 4,800 tex. Preferred thermoplastics in the nonwoven fabric or in the thermoplastic film are polypropylene and fusible polyamides, in particular aliphatic polyamides; In addition, other thermoplastics such as polyesters, polyethersulfone, polyether ketones and polyetherimide are suitable. Polyether ketones are characterized in particular by a good temperature resistance. Composites with particularly good flowability are obtained when the thermoplastic polypropylene with a melt flow index (MFI) (230 ° C, 2.16 kg) between 10 and 400, in particular at about 120 g / 10 min. The thermoplastics for making the nonwoven fabric layer A can be provided in very different dimensions and geometries. The individual layers of the composite material are sewn together as well as needled.
Beim Nähen werden die Faserbündel des Geleges miteinander durch einen Näh- faden verbunden, welcher Maschen bildet. Dadurch werden die Verstärkungsfasern in ihrer parallelen Orientierung fixiert. Geeignete Nähfäden können aus Glas, Polypropylen, Polyamid, sowie aus PET oder Polyetherketonen gebildet sein. Auch Acetat- und Viskosefäden können verwendet werden. Vorzugsweise sind die Nähfäden aus demselben Thermoplasten gebildet wie die Thermoplastfasern bzw. die Thermoplastfolie der Schicht A, vorzugsweise also aus Polypropylen bzw. Polyamid. When sewing, the fiber bundles of the fabric are joined together by a sewing thread, which forms stitches. As a result, the reinforcing fibers are fixed in their parallel orientation. Suitable sewing threads can be formed from glass, polypropylene, polyamide, as well as from PET or polyether ketones. Acetate and viscose threads can also be used. Preferably, the sewing threads are formed of the same thermoplastic as the thermoplastic fibers or the thermoplastic film of the layer A, preferably therefore of polypropylene or polyamide.
Die Figur 2 zeigt die Schichtanordnung B - A - B' der Figur 1 in einem Quer- schnitt entlang der Faserorientierung der Schicht B nach dem Vernähen. Der Nähfaden N verbindet dabei die Faserbündel der Schichten B' und B. In der Folge wird diese Schichtanordnung noch genadelt. FIG. 2 shows the layer arrangement B-A-B 'of FIG. 1 in a cross-section along the fiber orientation of the layer B after sewing. The sewing thread N connects the fiber bundles of the layers B 'and B. As a result, this layer arrangement is still needled.
Durch das Nadeln werden, wie bereits ausgeführt, die Faserbündel geöffnet und die Fasern werden teilweise gebrochen. Ausserdem werden durch die Widerhaken der Nadeln Thermoplastfasern aus dem Vlies in das Gelege hineingezogen. Ähnliches passiert auch beim Nadeln der Thermoplastfolie, wo durch die Widerhaken Bruchstücke bzw. Fäden aus der Folie herausgerissen und in das Gelege hinein gezogen werden. Das Nadeln kann auf üblichen Nadelstühlen mit Filzna- dein vorgenommen werden. Die Zahl der Nadelstiche kann zwischen 5 und 100 pro cm2, insbesondere zwischen 20 und 40 Einstiche pro cm2 liegen. By needling, as already stated, the fiber bundles are opened and the fibers are partially broken. In addition, the barbs of the needles draw thermoplastic fibers from the web into the scrim. The same thing happens when needling the thermoplastic film, where by the barbs fragments or threads torn out of the film and pulled into the scrim into it. Needling can be done on standard needle chairs with felt nails. The number of pinholes may be between 5 and 100 per cm 2 , in particular between 20 and 40 punctures per cm 2 .
Dies alles hat zur Folge, dass die Thermoplast-Schmelze aus dem Faservlies bzw. der Thermoplastfolie beim anschliessenden Heissverpressen in die Gelege- Schichten eindringen und diese gleichmässig tränken kann. Wenn der Nähfaden aus demselben Thermoplasten besteht, verschmilzt er beim Heissverpressen ebenfalls; er ist danach ohnehin nicht mehr erforderlich. All this has the consequence that the thermoplastic melt from the nonwoven fabric or the thermoplastic film can penetrate during the subsequent hot pressing in the Gelege- layers and this can soak evenly. When the sewing thread consists of the same thermoplastic, it also melts when hot-pressing; he is no longer required after that anyway.
Dadurch, dass die Faserbündel zusätzlich miteinander vernäht sind, behalten sie beim Nadeln ihre Orientierung bei, und da durch das Nähen auch die Gelege- Schicht mit der Faservlies-Schicht bzw. mit der Thermoplastfolie verbunden ist, besteht auch nicht die Gefahr, dass die Schichten beim Transport und bei der späteren Weiterverarbeitung verrutschen. Die erfindungsgemässen flächigen Verbundwerkstoffe können bei Temperaturen oberhalb des Erweichungsbereichs des Thermoplasten in Formen direkt zu dreidimensionalen Bauteilen verpresst werden, oder sie können durch Heissverpressen, z.B. in einer Doppelbandpresse, zu flächigen Halbzeugen, vorzugsweise mit einer Dicke von 0.5 bis 5 mm, konsolidiert werden. The fact that the fiber bundles are additionally sewn together, they maintain their orientation during needling, and since the Gelege- layer is connected to the nonwoven layer or with the thermoplastic film by sewing, there is also no risk that the layers slip during transport and during subsequent processing. The sheetlike composite materials according to the invention can be pressed directly into three-dimensional components at temperatures above the softening range of the thermoplastic in molds, or they can be pressed by hot pressing, e.g. in a double belt press, to flat semi-finished products, preferably with a thickness of 0.5 to 5 mm, be consolidated.

Claims

Patentansprüche claims
1 . Flächiger Verbundwerkstoff, umfassend 1 . Flat composite material comprising
- mindestens eine Schicht A aus einem Faservlies, bestehend aus 40 bis 100 Gew.-% Thermoplastfasern und 60 bis 0 Gew.-% Verstärkungsfasern, oder aus einer Thermoplastfolie, sowie  - At least one layer A of a nonwoven fabric consisting of 40 to 100 wt .-% thermoplastic fibers and 60 to 0 wt .-% reinforcing fibers, or from a thermoplastic film, and
- mindestens zwei unidirektionale Fasergelege-Schichten B und B' aus parallelen Verstärkungsfaserbündeln, wobei die Schichten B und B' eine bidirektionale Faserorientierung aufweisen,  at least two unidirectional fiber-laid layers B and B 'of parallel reinforcing fiber bundles, the layers B and B' having a bi-directional fiber orientation,
dadurch gekennzeichnet, dass die Schichten sowohl miteinander vernäht als auch genadelt sind.  characterized in that the layers are both sewn together and needled.
2. Verbundwerkstoffstoff nach Anspruch 1 , dadurch gekennzeichnet, dass die Schichtanordnung B - A - B' oder B - A - B' - A - B ist. 2. Composite material according to claim 1, characterized in that the layer arrangement B - A - B 'or B - A - B' - A - B is.
3. Verbundwerkstoff nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass die Faserorientierung der Schichten B und B' bezüglich einer Referenzrichtung des Verbundwerkstoffs 0° / 90°, 30 -30°, 45 -45° oder 607 -60° ist. 4. Verbundwerkstoff nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass die Flächengewichte der einzelnen Schichten jeweils 20 bis 1 Ό00 g/m2, insbesondere 30 bis 1 Ό00 g/m2, ganz besonders 150 is 300 g/m2, betragen. 5. Verbundwerkstoff nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass der Anteil der gesamten Verstärkungsfasern im Verbundwerkstoff 20 bis 80 Gew.-% beträgt. 3. The composite material according to claim 1 or 2, characterized in that the fiber orientation of the layers B and B 'with respect to a reference direction of the composite material 0 ° / 90 °, 30 -30 °, 45-45 ° or 607-60 °. 4. Composite material according to one of claims 1 to 3, characterized in that the basis weights of the individual layers each 20 to 1 Ό00 g / m 2 , in particular 30 to 1 Ό00 g / m 2 , especially 150 to 300 g / m 2 , be. 5. Composite material according to one of claims 1 to 4, characterized in that the proportion of the total reinforcing fibers in the composite material is 20 to 80 wt .-%.
6. Verbundwerkstoff nach einem der Ansprüche 1 bis 5, dadurch gekenn- zeichnet, dass die Verstärkungsfasern Glasfasern oder Kohlenstofffasern sind. 6. Composite material according to one of claims 1 to 5, characterized in that the reinforcing fibers are glass fibers or carbon fibers.
7. Verbundwerkstoff nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass die Thernnoplastfasern bzw. die Thernnoplastfolie der Schicht A aus Polypropylen gebildet sind. 7. Composite material according to one of claims 1 to 6, characterized in that the Thernnoplastfasern or the Thernnoplastfolie the layer A are formed from polypropylene.
Verbundwerkstoff nach Anspruch 7, dadurch gekennzeichnet, dass die Nähfäden aus einem Polypropylen gebildet sind. Composite material according to claim 7, characterized in that the sewing threads are formed from a polypropylene.
Verbundwerkstoff nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass die Thermoplastfasern bzw. die Thermoplastfolie der Schicht A aus einem Polyamid gebildet sind. Composite material according to one of claims 1 to 6, characterized in that the thermoplastic fibers or the thermoplastic film of the layer A are formed from a polyamide.
10. Verbundwerkstoff nach Anspruch 9, dadurch gekennzeichnet, dass die 10. Composite material according to claim 9, characterized in that the
Nähfäden aus einem Polyamid gebildet sind.  Sewing threads are formed from a polyamide.
Verbundwerkstoff nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass die Thermoplastfasern bzw. die Thermoplastfolie der Schicht A aus einem Polyetherketon gebildet sind. Composite material according to one of claims 1 to 6, characterized in that the thermoplastic fibers or the thermoplastic film of the layer A are formed from a polyether ketone.
12. Verbundwerkstoff nach Anspruch 1 1 , dadurch gekennzeichnet, dass die Nähfäden aus einem Polyetherketon gebildet sind. 12. A composite material according to claim 1 1, characterized in that the sewing threads are formed from a polyether ketone.
Verfahren zur Herstellung des Verbundwerkstoffs nach Anspruch 1 , dadurch gekennzeichnet, dass entweder: Method for producing the composite material according to claim 1, characterized in that either:
zunächst die Faservlies-Schicht(en) A nach dem Krempel-, Airlay- oder Spinnvlies-Verfahren hergestellt werden, und dass dann kontinuierlich die Gelege-Schichten B und B' mit der bzw. den Faservlies-Schicht(en) A zusammengeführt werden, dann die Schichten miteinander vernäht und anschliessend genadelt werden;  first the nonwoven layer (s) A are produced by the carding, airlay or spunbonding process, and then the scrim layers B and B 'are continuously brought together with the nonwoven layer (s) A, then the layers are sewn together and then needled;
oder: dass die Thermoplastfolie(n) der Schicht A und die Gelegeschichten B und B' kontinuierlich zusammengeführt werden, dann die Schichten miteinander vernäht und anschliessend genadelt werden. or: that the thermoplastic film (s) of the layer A and the gel layers B and B 'are brought together continuously, then the layers are sewn together and then needled.
Verwendung des Verbundwerkstoffs nach einem der Ansprüche 1 bis 12 zur Herstellung von dreidimensionalen Bauteilen durch Heissverpressen in einer Form. Use of the composite material according to one of claims 1 to 12 for the production of three-dimensional components by hot pressing in a mold.
15. Verwendung des Verbundwerkstoffs nach einem der Ansprüche 1 bis 12 zur Herstellung eines flächigen Halbzeugs einer Dicke von 0.5 bis 5 mm durch Heissverpressen in einer Doppelbandpresse. 15. Use of the composite material according to one of claims 1 to 12 for the production of a flat semifinished product of a thickness of 0.5 to 5 mm by hot pressing in a double belt press.
EP13707292.2A 2012-02-08 2013-02-08 Sheetlike composite material Withdrawn EP2812184A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP13707292.2A EP2812184A1 (en) 2012-02-08 2013-02-08 Sheetlike composite material

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP12154516.4A EP2626200A1 (en) 2012-02-08 2012-02-08 Flat compound material
EP13707292.2A EP2812184A1 (en) 2012-02-08 2013-02-08 Sheetlike composite material
PCT/EP2013/052616 WO2013117743A1 (en) 2012-02-08 2013-02-08 Sheetlike composite material

Publications (1)

Publication Number Publication Date
EP2812184A1 true EP2812184A1 (en) 2014-12-17

Family

ID=47790146

Family Applications (2)

Application Number Title Priority Date Filing Date
EP12154516.4A Ceased EP2626200A1 (en) 2012-02-08 2012-02-08 Flat compound material
EP13707292.2A Withdrawn EP2812184A1 (en) 2012-02-08 2013-02-08 Sheetlike composite material

Family Applications Before (1)

Application Number Title Priority Date Filing Date
EP12154516.4A Ceased EP2626200A1 (en) 2012-02-08 2012-02-08 Flat compound material

Country Status (4)

Country Link
US (3) US20150030804A1 (en)
EP (2) EP2626200A1 (en)
CN (1) CN104169077B (en)
WO (1) WO2013117743A1 (en)

Families Citing this family (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2508078A (en) * 2012-09-19 2014-05-21 Hexcel Composites Ltd Non-woven moulding reinforcement material
CN104088054B (en) * 2014-07-04 2016-07-06 浙江理工大学 A kind of preparation method of behavior of polypropylene composites high-performance recombination line
CN104859155A (en) * 2015-05-11 2015-08-26 华东理工大学 Method for manufacturing continuous fiber-reinforcement thermoplastic plate with three-dimensional structure
CN106003876A (en) * 2016-05-18 2016-10-12 中国电子科技集团公司电子科学研究院 Composite avoiding tearing during riveting and laying method
CN107059780A (en) * 2016-12-28 2017-08-18 上海蓝坤环境科技有限公司 Disappear for navigable river and fall the multilayer materials and processing method of section ecological revetment
CN106677129B (en) * 2016-12-28 2018-11-02 上海蓝坤环境科技有限公司 A kind of processing method of the network structure of dotted needle thorn composite skins hot melt antiscour
EP3385069A1 (en) * 2017-04-03 2018-10-10 Quadrant Plastic Composites AG Method of forming a flat composite component and composite component produced in this way
DE102018000421A1 (en) 2017-12-21 2019-06-27 H.K.O. Isolier- Und Textiltechnik Gmbh Multilayer thermal insulation element for batteries
US11111610B2 (en) * 2018-06-26 2021-09-07 GM Global Technology Operations LLC Methods for forming composite articles from non-crimp fabrics
MX2021001885A (en) 2018-08-21 2021-04-19 Owens Corning Intellectual Capital Llc Multiaxial reinforcing fabric with a stitching yarn for improved fabric infusion.
US11913148B2 (en) 2018-08-21 2024-02-27 Owens Corning Intellectual Capital, Llc Hybrid reinforcement fabric
US11807355B2 (en) * 2019-06-28 2023-11-07 The Boeing Company Landing gear system with composite flex beam
WO2021237376A1 (en) * 2020-05-23 2021-12-02 江苏莘翔机电股份有限公司 Lft-d in-mold film coating process for building formwork
CN115195160B (en) * 2022-07-07 2023-11-03 湖南弘辉科技有限公司 Method for stitching and compression molding of metal piece and composite material layer

Family Cites Families (23)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1860090A (en) * 1930-11-29 1932-05-24 Del Roy F Fowler Padding rug
NL128503C (en) * 1965-03-04 1900-01-01
US3395065A (en) * 1967-10-06 1968-07-30 Beacon Mfg Co Non-woven blanket fabric and method
US3260640A (en) * 1965-03-04 1966-07-12 Beacon Mfg Co Stitched and needled non-woven fabric
US3329552A (en) * 1966-06-16 1967-07-04 Beacon Mfg Co Stitched non-woven fabric
US3616124A (en) * 1968-05-31 1971-10-26 Vyzk Ustav Pletarsky Composite nonwoven fabric
US3761345A (en) * 1969-04-03 1973-09-25 R Smith Nonwoven structure for reinforcing resinous material
US3614936A (en) * 1969-05-09 1971-10-26 Owens Corning Fiberglass Corp Nonwoven reinforcement structure and method for producing it
GB8513608D0 (en) * 1985-05-30 1985-07-03 Otty M Reinforced resinous material
GB8822520D0 (en) * 1988-09-26 1988-11-02 Tech Textiles Ltd Process for continuously forming reinforced plastics articles
US5843557A (en) * 1994-02-14 1998-12-01 Sternlieb; Herschel Conformable structural reinforcement substrate and method of making same
US6105223A (en) * 1997-04-30 2000-08-22 The B. F. Goodrich Company Simplified process for making thick fibrous structures
US5910458A (en) * 1997-05-30 1999-06-08 Ppg Industries, Inc. Glass fiber mats, thermosetting composites reinforced with the same and methods for making the same
JP4491968B2 (en) * 1999-03-23 2010-06-30 東レ株式会社 Composite carbon fiber substrate, preform, and method for producing carbon fiber reinforced plastic
US6881288B2 (en) * 1999-06-21 2005-04-19 Pella Corporation Method of making a reinforcing mat for a pultruded part
DE10105813A1 (en) * 2001-02-08 2002-08-14 Quadrant Plastic Composites Ag Process for the production of a thermoplastically deformable, fiber-reinforced semi-finished product
WO2004109213A2 (en) * 2002-09-10 2004-12-16 Tex Tech Industries, Inc. Enhanced energy absorbing materials
US20040219855A1 (en) * 2003-05-02 2004-11-04 Tsotsis Thomas K. Highly porous interlayers to toughen liquid-molded fabric-based composites
WO2005033393A1 (en) * 2003-09-30 2005-04-14 Fabrics Technologies Llc Fiber-reinforced thermoplastic composite materials and method of manufacturing the same
DE102005017970B4 (en) 2005-04-19 2014-05-28 Audi Ag Charger module for an internal combustion engine
EP1714772A1 (en) 2005-04-20 2006-10-25 Quadrant Plastic Composites AG Composite thermoplastic intermediate product
FR2921076B1 (en) * 2007-09-18 2010-04-02 Roy Guy Le HIGH STRUCTURAL RESISTANCE PANEL, DEVICE AND METHOD FOR MANUFACTURING SUCH PANEL
JP6672003B2 (en) * 2015-02-19 2020-03-25 日本バイリーン株式会社 Nonwoven fabric for molding and skin material for automobiles

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO2013117743A1 *

Also Published As

Publication number Publication date
US20200238659A1 (en) 2020-07-30
US20150030804A1 (en) 2015-01-29
CN104169077B (en) 2017-02-22
CN104169077A (en) 2014-11-26
WO2013117743A1 (en) 2013-08-15
US20180001594A1 (en) 2018-01-04
EP2626200A1 (en) 2013-08-14

Similar Documents

Publication Publication Date Title
WO2013117743A1 (en) Sheetlike composite material
EP2536546B1 (en) Method for producing a flat semi-finished product from fiber composite material, and the obtained semi-finished product
EP2791409B1 (en) Flat compound material
EP1901912B1 (en) Thermoplastically processable composite material
EP1593490B1 (en) Process of making a plane semi-finished product
EP2903794B1 (en) Method for manufacturing a semi-finished product for producing a composite moulded part
EP1772258B1 (en) Use of a web laminate for production of fibre-reinforced parts and fibre-reinforced part
EP1372940A1 (en) Method of producing a thick, thermoformable, fiber-reinforced semi-finished product
WO2012065598A2 (en) Hybrid yarn, method for the production of fiber preforms for fiber composite components, in particular high-strength fiber composite components, using said hybrid yarn, and method for the production of fiber composite components, in particular high-strength fiber composite components
WO2002062563A1 (en) Method for producing a thermoplastically deformable, fibre-reinforced semi-finished product
DE102008061314A1 (en) Process for the production of fiber layers, as well as fiber fabrics and their use
EP1373375B1 (en) Method of producing a thermoformable, fiber-reinforced semi-finished product on the basis of polyether imides
EP0697275B1 (en) Fiber reinforced material having high bending stiffness
WO2015104178A1 (en) Fiber composite material and method for the production thereof
EP1719611A1 (en) Method for producing a thermoplastically deformable, fibre-reinforced semi-finished product
DE4444505C2 (en) Self-adhesive reinforcing material, process for its production and use for the production of textile nonwovens
DE102004022464B4 (en) Molded part for the interior decoration of vehicles
EP3227485B1 (en) Textile product, method for producing said textile product and uses of said textile product
EP2871052B1 (en) Motor vehicle interior section
DE10230235B4 (en) Semi-finished sheet material for composite materials
EP1242662A2 (en) Moulded part consisting of a nonwoven fabric and self-supporting moulded part produced from the same

Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

17P Request for examination filed

Effective date: 20140630

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

AX Request for extension of the european patent

Extension state: BA ME

DAX Request for extension of the european patent (deleted)
STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE APPLICATION IS DEEMED TO BE WITHDRAWN

18D Application deemed to be withdrawn

Effective date: 20150327