EP2813607B1 - Gewebe aus imprägniertem tuch und verfahren zur herstellung eines gewebes aus imprägniertem garn - Google Patents

Gewebe aus imprägniertem tuch und verfahren zur herstellung eines gewebes aus imprägniertem garn Download PDF

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Publication number
EP2813607B1
EP2813607B1 EP13746246.1A EP13746246A EP2813607B1 EP 2813607 B1 EP2813607 B1 EP 2813607B1 EP 13746246 A EP13746246 A EP 13746246A EP 2813607 B1 EP2813607 B1 EP 2813607B1
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EP
European Patent Office
Prior art keywords
impregnated
yarn cloth
yarn
fiber bundles
cloth
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.)
Active
Application number
EP13746246.1A
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English (en)
French (fr)
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EP2813607A1 (de
EP2813607A4 (de
Inventor
Hodaka Miura
Naoyuki Tashiro
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.)
Kobe Steel Ltd
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Kobe Steel Ltd
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Publication date
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Publication of EP2813607A1 publication Critical patent/EP2813607A1/de
Publication of EP2813607A4 publication Critical patent/EP2813607A4/de
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Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
    • D06B1/00—Applying liquids, gases or vapours onto textile materials to effect treatment, e.g. washing, dyeing, bleaching, sizing or impregnating
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
    • D03D15/41—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads with specific twist
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/40—Yarns in which fibres are united by adhesives; Impregnated yarns or threads
    • D02G3/404—Yarns or threads coated with polymeric solutions
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D1/00—Woven fabrics designed to make specified articles
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D49/00—Details or constructional features not specially adapted for looms of a particular type
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B35/00—Details of, or auxiliary devices incorporated in, knitting machines, not otherwise provided for
    • D04B35/22—Devices for preparatory treatment of threads
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00—Inorganic fibres
    • D10B2101/02—Inorganic fibres based on oxides or oxide ceramics, e.g. silicates
    • D10B2101/06—Glass
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00—Inorganic fibres
    • D10B2101/10—Inorganic fibres based on non-oxides other than metals
    • D10B2101/12—Carbon; Pitch
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/04—Heat-responsive characteristics
    • D10B2401/041—Heat-responsive characteristics thermoplastic; thermosetting
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/01—Surface features
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/02—Reinforcing materials; Prepregs

Definitions

  • the present invention relates to an impregnated-yarn cloth which is a knitted or woven fabric configured of impregnated yarns, and a process for producing the impregnated-yarn cloth.
  • a sheet-like impregnated cloth such as a prepreg is generally used as a material in formation of a molded object of fiber-reinforced resin.
  • This impregnated cloth is obtained by coating the surface of a base material, which is a textile fabric obtained by knitting or weaving fiber bundles, with a thermoplastic resin.
  • a base material which is a textile fabric obtained by knitting or weaving fiber bundles
  • thermoplastic resin When this impregnated cloth is heated, the thermoplastic resin coating the surface of the base material is molten, so that the base material constrained by the thermoplastic resin can be deformed (shaped).
  • the thermoplastic resin is cooled and solidified after molding the impregnated cloth into a desired shape, whereby the sheet-like impregnated cloth can be made into the molded object.
  • the base material can hardly be deformed unless the coating thermoplastic resin is plasticized.
  • the impregnated cloth can hardly be deformed into an optional shape of molded object.
  • Patent Document 1 discloses a process of preliminarily coating each fiber of fiber bundles with a thermoplastic resin before knitting or weaving the fiber bundles into a cloth state to form an impregnated yarn, and knitting or weaving such impregnated yarns to obtain an impregnated-yarn cloth.
  • Patent Document 1 JP 04-185313 A
  • the impregnated-yarn cloth obtained by the process of Patent Document 1 is easily deformable, compared with the above-mentioned impregnated cloth, since each of the impregnated yarns is relatively freely movable, and thus has satisfactory shaping properties.
  • each impregnated yarn constituting this impregnated-yarn cloth is extremely rigid and cannot be freely bent since it is constituted by solidifying fiber bundles of single fibers neatly aligned in one direction by coating with the thermoplastic resin.
  • the aperture inevitably becomes large to avoid breakage of the single fibers.
  • a molded object having high strength can hardly be obtained since the density of the fiber bundles in the molded object is insufficient.
  • the strength of the impregnated-yarn cloth or molded object can be rather deteriorated due to unnecessary curling of the impregnated yarns or peeling of the thermoplastic resin from the surface of the fiber bundles.
  • the present invention has an object to provide a process for producing an impregnated-yarn cloth, which has a small aperture of impregnated yarns while having satisfactory shaping properties, and which can provide a molded object having excellent strength with high productivity, and an impregnated-yarn cloth obtained by the method.
  • a process for producing an impregnated-yarn cloth of the present invention takes the following technical means.
  • the above object is solved with a process for producing an impregnated-yarn cloth having the features of claim 1 and an impregnated-yarn cloth having the features of claim 3. Further embodiments are laid down in the sub-claims.
  • an impregnated-yarn cloth 1 is formed using an impregnated yarn 3 composed of fiber bundles 2 (reinforced fiber bundles) coated with a thermoplastic resin 5, and is constituted by knitting or weaving a plurality of impregnated yarns 3.
  • the impregnated-yarn cloth 1 of the present invention is obtained by knitting or weaving the impregnated yarns 3 that are resin composite materials.
  • the impregnated yarn 3 constituting the impregnated-yarn cloth 1 of the present invention, and the knitted or woven state of the impregnated yarn 3 are further described in detail below.
  • the impregnated yarn 3 constituting the impregnated-yarn cloth 1 includes the fiber bundles 2 which enhance mechanical characteristics (tensile strength, etc.) of a molded object 4 and the thermoplastic resin 5 which coats the surface (circumference) of the fiber bundles 2 over the longitudinal direction.
  • Each of the fiber bundles 2 is formed by bundling single fibers by a number to be described later, and the single fibers are formed from fibers capable of reinforcing the thermoplastic resin 5 that is a matrix.
  • the fiber bundle 2 for example, a fiber such as glass fiber, carbon fiber or aramid fiber can be used.
  • the above-mentioned single fibers are bundled at a rate of 500 tex or more and 15,000 tex or less (JIS L0101), and the outside diameter (diameter) of each fiber bundle 2 is 0.3 mm ⁇ or more and 3.0 mm ⁇ or less.
  • the thermoplastic resin 5 covers the surface of the fiber bundles 2 of the impregnated yarn 3.
  • the thermoplastic resin 5 functions also as a binder for binding the mutually knitted or woven fiber bundles 2, when forming the molded object 4, by being interposed between the both.
  • a polyolefin resin such as polypropylene or polyethylene can be used as the thermoplastic resin 5.
  • a polyamide resin such as nylon and a resin such as PET, PBT, PEI, or PEEK can be also used.
  • the above-mentioned impregnated yarns 3 may be knitted or may be woven.
  • a knitting method such as flat knitting, hosiery knitting, rib knitting, chain knitting, or garter knitting can be adopted.
  • a weaving method such as twill weave or satin weave can be adopted in addition to flat weave as shown in Figs. 1 .
  • each piece of the impregnated yarns 3 is formed by solidifying single fibers neatly aligned in one direction by coating the circumference thereof with the thermoplastic resin 5. Since impregnated yarns 3 obtained by such a method are rigid and inflexible, and give a large aperture when knitted or woven, sufficient strength as the impregnated-yarn cloth 1 cannot be obtained. Further, since the impregnated yarns 3 obtained by the conventional method are hardly bendable in knitting or weaving, efficient production of the impregnated-yarn cloth 1 can often be difficult (refer to the description of Technical Problem).
  • the impregnated-yarn cloth 1 of the present invention fiber bundles 2 formed by a plurality of single fibers are twisted so that the twist number is 20 twists/m or more and 50 twists/m or less. Since the flexibility of each impregnated yarn 3 is enhanced by setting the twist number of the fiber bundles 2 to 20 twists/m or more and 50 twists/m or less, the aperture can be reduced when knitted or woven into the impregnated-yarn cloth 1, and the mechanical strength (tensile strength) of the impregnated-yarn cloth 1 can be improved more than in the past. Further, since the enhanced flexibility of the impregnated yarns 3 facilitates the bending of the impregnated yarns 3 in knitting or weaving, the productivity in knitting or weaving into the impregnated-yarn cloth 1 can be also enhanced.
  • the twisting direction of the fiber bundles 2 may be right or left.
  • the number of fiber bundles 2 used in one impregnated yarn 3 is 2 or more and 10 or less.
  • the impregnated-yarn cloth 1 of the present invention is knitted or woven at an aperture of 0 mm or more and 10 mm or less by being knitted or woven using impregnated yarns 3 having a twist number as described above.
  • the impregnated-yarn cloth 1 having such an aperture can form a molded object 4 excellent in mechanical strength by supplying the fiber bundles 2 into the molded object 4 by a sufficient density.
  • the process for producing an impregnated-yarn cloth 1 of the present invention comprises: a first step 7 of impregnating fiber bundles 2 with a thermoplastic resin 5 held in a molten state in a resin tank (impregnation unit 12) to form an impregnated yarn 3 in which the fiber bundles 2 are twisted; and a second step 8 of knitting or weaving the impregnated yarns 3 formed in the first step 7 to obtain the impregnated-yarn cloth 1 of a resin composite material.
  • the production apparatus 9 includes a hopper 10 for supplying pellets of the thermoplastic resin 5.
  • the pellets of the thermoplastic resin 5 supplied from the hopper 10 are kneaded in a kneading unit 11 disposed adjacently to the hopper 10.
  • the thermoplastic resin 5 plasticized in the kneading unit 11 is sent to an impregnation unit 12, and stored in the impregnation unit 12.
  • the impregnation unit 12 is formed into a long bottomed cylindrical shape having a vertical axis so that the plasticized thermoplastic resin 5 can be stored, and is opened upward. A plurality of fiber bundles 2 wound off from bobbins disposed on a lateral side of the impregnation unit 12 are fed into the impregnation unit 12 through this upper opening.
  • the plurality of fiber bundles 2 are supplied from the bobbins which are provided by the same number as the number of the fiber bundles 2 respectively, preheated by a preheater 13, and then fed into the impregnation unit 12 via an upper guide roll 14.
  • a die nozzle 15 for extruding the fiber bundles 2 fed out of the impregnation unit 12 through the upper opening is provided on the lower side of the impregnation unit 12, so that the die nozzle 15 can be used to coat the surface of the fiber bundles 2 with the thermoplastic resin 5 by a predetermined thickness. Further, between the upper opening and the die nozzle 15 within the impregnation unit 12, a lower guide roll (not shown) for transferring the fiber bundles 2 in a laid-over state is disposed in dipping in the molten thermoplastic resin 5.
  • a water tank 16 for promoting the cooling and curing of the thermoplastic resin 5 coating the surface of the fiber bundles 2 is provided on the downstream side of the impregnation unit 12.
  • a winder 17 (twisting roller device) for twisting the fiber bundles 2 cooled in the water tank 16 is provided on the downstream side of the water tank 16.
  • This winder 17 is configured to rotate a roller (uncoiler) so as to be twisted around an axis along the transfer direction of the fiber bundles 2 while taking up the fiber bundles 2 by the roller around an axis orthogonal to the transfer direction of the fiber bundles 2.
  • the impregnated yarn 3 can be formed while twisting the fiber bundles 2 at a rate of 20 twists/m or more and 50 twists/m or less.
  • the impregnated yarns 3 formed in the first step 7 are knitted or woven to form the impregnated-yarn cloth 1.
  • a known knitting machine or weaving machine can be used for the second step 8, and the impregnated yarns 3 are knitted or woven by a desired knitting or weaving method using the knitting machine or weaving machine, whereby the impregnated-yarn cloth 1 is formed.
  • the knitting machine or weaving machine used for the second step 8 is not illustrated herein.
  • the impregnated-yarn cloth 1 thus formed by knitting or weaving in the second step 8 is hot-pressed along a desired shape, whereby a molded object 4 can be formed from the impregnated-yarn cloth 1 as shown by the dotted line in Fig. 2 .
  • each of the fiber bundles 2 constituting this impregnated-yarn cloth 1 is twisted at a rate of 20 twists/m or more and 50 twists/m or less. Therefore, the flexibility of the fiber bundles 2 is high, compared with one in which fiber bundles are neatly aligned along one direction, and can be freely bent or distorted when made into the impregnated yarn 3.
  • the aperture can be reduced, and the mechanical strength (tensile strength) of the impregnated-yarn cloth 1 can be improved more than in the past by closely knitting or weaving the impregnated yarns 3.
  • the enhanced flexibility of the impregnated yarns 3 facilitates the bending of the impregnated yarns 3 in knitting or weaving, and the productivity in knitting or weaving into the impregnated-yarn cloth 1 can be also enhanced.
  • the impregnated yarns 3 having such twists are excellent also in mechanical strength such as tensile strength, and the strength of the impregnated-yarn cloth 1 itself is also enhanced. Therefore, when the impregnated-yarn cloth 1 of the present invention is used, a molded object 4 having excellent strength in which the fiber bundles 2 are closely arranged as shown in Fig. 1(c) can be obtained.
  • Example 1 to Example 3 were prepared.
  • a fiber bundle 2 used for the impregnated-yarn cloth 1 in Example 1 is formed by bundling single fibers of glass fiber so as to have a count of 4620 tex, and it has an outside diameter of 3.0 mm ⁇ .
  • a fiber bundle 2 used for the impregnated-yarn cloth 1 in Example 2 is formed by bundling single fibers of glass fiber so as to have a count of 575 tex, and it has an outside diameter of 1.05 mm ⁇ .
  • a fiber bundle 2 used for the impregnated-yarn cloth 1 in Example 3 is formed by bundling single fibers of carbon fiber so as to have a count of 15,000 tex, and it has an outside diameter of 1.7 mm ⁇ .
  • Example 1 shown by black rhombi in Fig. 4(a) , when the twist number in the winder is increased from 0 twist/m to 25 twists/m, the tensile strength is also increased in accordance with this increase. Relatively high tensile strength is maintained in the twist number range of 25 to 75 twists/m. However, when the twist number in the winder exceeds 75 twists/m, the tensile strength is suddenly reduced against the increase in twist number.
  • Example 2 shown by black squares in Fig. 4(a)
  • Example 3 shown by black circles in Fig. 4(b)
  • relatively high tensile strength is maintained in the twist number range of 18 to 60 twists/m.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Woven Fabrics (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Reinforced Plastic Materials (AREA)

Claims (4)

  1. Verfahren zum Herstellen eines imprägnierten Garngewebes (1), dadurch gekennzeichnet, dass es aufweist:
    Tränken von Faserbündeln (2, 2) in einem thermoplastischen Harz (5), das in einem geschmolzenen Zustand in einem Harztank (12) gespeichert ist, während oder nachdem die Faserbündel (2, 2) bei einer Rate von 20 Verdrillungen pro Meter oder mehr und 50 Verdrillungen pro Meter oder weniger gegenseitig verdrillt werden, um einen imprägnierten Garn (3) auszubilden, Ausbilden einer Vielzahl solcher imprägnierter Garne (3); und
    gegenseitiges Verstricken oder Verweben der dadurch ausgebildeten imprägnierten Garne (3), um das imprägnierte Garngewebe (1) zu erhalten.
  2. Verfahren zum Herstellen eines imprägnierten Garngewebes (1) nach Anspruch 1,
    wobei die imprägnierten Garne (3) verstrickt oder verwebt werden, sodass eine Maschenweite des imprägnierten Garngewebes (1) 0 mm oder mehr und 10 mm oder weniger beträgt.
  3. Imprägniertes Garngewebe (1), dadurch gekennzeichnet, dass imprägnierte Garne (3) gegenseitig verstrickt oder verwebt sind, wobei die imprägnierten Garne (3) durch verdrillte Faserbündel ausgebildet sind, welche bei einer Rate von 20 Verdrillungen pro Meter oder mehr und 50 Verdrillungen pro Meter oder weniger gegenseitig verdrillt sind, wobei die gegenseitig verdrillten Faserbündel mit einem thermoplastischen Harz ummantelt sind.
  4. Imprägniertes Garngewebe (1) nach Anspruch 3, wobei die imprägnierten Garne (3) verstrickt oder verwebt sind, sodass eine Maschenweite des imprägnierten Garngewebes 0 mm oder mehr und 10 mm oder weniger beträgt.
EP13746246.1A 2012-02-09 2013-01-29 Gewebe aus imprägniertem tuch und verfahren zur herstellung eines gewebes aus imprägniertem garn Active EP2813607B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2012026363A JP6021343B2 (ja) 2012-02-09 2012-02-09 含浸糸布及び含浸糸布の製造方法
PCT/JP2013/051808 WO2013118604A1 (ja) 2012-02-09 2013-01-29 含浸糸布及び含浸糸布の製造方法

Publications (3)

Publication Number Publication Date
EP2813607A1 EP2813607A1 (de) 2014-12-17
EP2813607A4 EP2813607A4 (de) 2015-12-02
EP2813607B1 true EP2813607B1 (de) 2020-03-11

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EP13746246.1A Active EP2813607B1 (de) 2012-02-09 2013-01-29 Gewebe aus imprägniertem tuch und verfahren zur herstellung eines gewebes aus imprägniertem garn

Country Status (7)

Country Link
US (1) US20140366347A1 (de)
EP (1) EP2813607B1 (de)
JP (1) JP6021343B2 (de)
KR (1) KR101666287B1 (de)
CN (1) CN104105825A (de)
ES (1) ES2779037T3 (de)
WO (1) WO2013118604A1 (de)

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TW201937027A (zh) * 2018-02-23 2019-09-16 台灣勁合有限公司 織物結構
DE102018001440A1 (de) * 2018-02-23 2019-08-29 Delcotex Delius Techtex Gmbh & Co. Kg Fadenstruktur
FR3103199B1 (fr) 2019-11-15 2021-12-10 Bcomp Sa Fil imprégné, produit composite à paroi mince nervuré comportant un tel fil imprégné, et procédé de fabrication de ce fil et de ce produit composite

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Publication number Publication date
ES2779037T3 (es) 2020-08-13
CN104105825A (zh) 2014-10-15
JP2013163870A (ja) 2013-08-22
EP2813607A1 (de) 2014-12-17
KR20140111019A (ko) 2014-09-17
WO2013118604A1 (ja) 2013-08-15
JP6021343B2 (ja) 2016-11-09
KR101666287B1 (ko) 2016-10-13
EP2813607A4 (de) 2015-12-02
US20140366347A1 (en) 2014-12-18

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