EP3452651B1 - Textile nonwoven sheet product which is capable of rolling - Google Patents

Textile nonwoven sheet product which is capable of rolling Download PDF

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Publication number
EP3452651B1
EP3452651B1 EP17721088.7A EP17721088A EP3452651B1 EP 3452651 B1 EP3452651 B1 EP 3452651B1 EP 17721088 A EP17721088 A EP 17721088A EP 3452651 B1 EP3452651 B1 EP 3452651B1
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Prior art keywords
fibers
sheet product
nonwoven sheet
fiber
product according
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EP17721088.7A
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German (de)
French (fr)
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EP3452651A1 (en
Inventor
Cordula CLEFF
Jan Maidorn
Hagen Hohmuth
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Tenowo GmbH
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Tenowo GmbH
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Classifications

    • 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
    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4242—Carbon fibres
    • 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
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • 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
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres

Definitions

  • the invention relates to a rollable textile nonwoven sheet product, consisting of a mixture of recycled carbon fibers and thermoplastic fibers, which are laid into a fiber pile by means of a carding process, subjected to a fleece formation and then thermally bonded, according to the preamble of claim 1.
  • the fiber composite material has fibers and at least one thermoplastic matrix material.
  • the aforementioned fibers are isolated from fiber-containing waste or old parts and mixed with thermoplastic fibers and laid flat in a carding process so that a fiber pile is produced.
  • a plate material is formed under the action of heat in the form of a pressing step.
  • carbon fibers that are available at low cost can be used as reinforcing fibers.
  • carbon fibers, carbon fiber bundles or their mixtures are isolated from carbon fiber-containing waste or old parts and these are mixed with thermoplastic foreign fibers.
  • flat laying down and alignment takes place in such a way that a fiber web is created with a targeted orientation of the fibers in the longitudinal direction.
  • the already mentioned pressing is then carried out under the action of heat to form a plate material.
  • FIG WO 2011 / 101094A1 proposed adding foreign textile fibers, such as polypropylene, to increase the degree of fiber orientation of the carbon fibers as well.
  • Auxiliary fibers are used to specifically influence the degree of fiber orientation of carbon fibers.
  • the oriented carbon fibers are brought into an adhesive state through the proportion of thermoplastic fibers with subsequent compression and compression to form sheet goods and finally cooling.
  • pressing takes place at a pressure of 400 N / cm 2 , in the sense of compacting.
  • thermoplastic component used being a fibrous material made from polyhydroxyether.
  • the EP 1 772 258 B1 discloses a laminate structure of a plastic part with coarse fibers of ⁇ 10 dtex.
  • the composite material consists of aligned reinforcing fibers embedded in a thermoplastic matrix, a scrim made from the aligned reinforcing fibers and thermoplastic material and the thermoplastic material being heated to a temperature above its melting point.
  • reinforcing fibers carbon fibers come into consideration.
  • the EP 2,886,693 discloses a rollable textile nonwoven sheet product consisting of a mixture of recycled carbon fibers and thermoplastic fibers, which is laid into a fiber web by means of a carding process, subjected to a nonwoven formation and then thermally bonded.
  • the object of the invention to provide a further developed rollable, i.e. Rollable or windable textile nonwoven sheet product, consisting of a mixture of recycled carbon fibers and thermoplastic fibers, to indicate which has an open-pore nonwoven structure, so that a later further treatment, e.g. Impregnation with a resin is possible in a simple manner.
  • the nonwoven sheet product to be created should retain the carbon fibers used in their original consistency, i.e.
  • One of the main goals is to keep the carbon fiber content as high as possible, but also to ensure the mentioned impregnation properties and to minimize the generation of dust from unbound fiber pieces.
  • a rollable and therefore easy to handle textile nonwoven sheet product which consists of a mixture of recycled carbon fibers and thermoplastic fibers. This mixture is laid into a fiber web by means of a carding process, subjected to a fleece formation and then thermally bonded, specifically in the sense of a pre-consolidation.
  • thermoplastic fibers in the mixture is in the range from 5% by weight to 40% by weight and the proportion of carbon fibers in the range between 60% by weight and 95% by weight, the thermal bonding to avoid carbon fiber damage under low pressure of ⁇ 20 N / cm 2 takes place in such a way that the desired open-pored, impregnable fleece structure is retained.
  • the fiber fineness of the carbon fibers used is in the range ⁇ 1 dtex.
  • the cut length of the carbon fibers is in the range between 30 mm and 80 mm.
  • the fiber fineness of the thermoplastic fibers is in the range between 1.0 and 4.0 dtex.
  • the cut length of the thermoplastic fibers is in the range between 30 mm and 70 mm.
  • the fiber mixture is subjected to a solidification by increasing the temperature in the range up to 200 ° C and subsequent cooling, whereby a melting of the thermoplastic fibers is prevented, but the fibers are melted to connect with the carbon fibers.
  • the nonwoven sheet product obtained has an open-pored, good impregnation property, but also a very uniform, high-quality surface.
  • the carbon fibers are not damaged or only slightly damaged by the measures according to the invention during the solidification process, so that there is no reduction in strength in the later composite material and disadvantageous dust generation from unbound fiber pieces.
  • the fiber web is produced using a carding process.
  • the proportion of carbon fibers is chosen as high as possible, since the added proportion of thermoplastics is a foreign component.
  • a bicomponent fiber one of the components has a lower melting point than the other, second component.
  • the recycled carbon fibers used can be, for example, cut roving residues, pre-dissolved scraps of scrim or fabric, edge sections, Fibers that come from carbon fiber-reinforced plastics and have been recovered there by means of thermal, chemical or other processing.
  • a hot calender, a smoothing unit, a belt calender, a shirt collar press, a belt press or a hot ironer are used as the consolidation unit, whereby a modification is made such that the pressure applied is in the range ⁇ 2 bar, i.e. ⁇ 20 N / cm 2 , to avoid fiber damage definitely to avoid.
  • the resulting goods are wound up gently and with little tension by means of an ascending batch winder.
  • the weight of the nonwoven fabric obtained is in the range from 50 to 200 g / m 2 , preferably in the range between 80 to 150 g / m 2 .
  • the strength properties of the nonwoven sheet product are low compared to the weight per unit area, but far more than sufficient to ensure both the desired winding and positive handling during subsequent processing.
  • further components of high-performance fibers from recycling processes can be mixed in in addition to the carbon fiber content.
  • This can be, for example, aramid fibers, glass fibers, basalt fibers or the like.
  • care must be taken to ensure that the proportion of thermoplastic fibers of 5% by weight to a maximum of 40% by weight is maintained and not exceeded.
  • the material can be wet-finished with chemical substances, with these substances then reacting out by means of a drying and fixing process.
  • the nonwoven sheet product can be pre-impregnated with resin to obtain a prepreg.
  • nonwoven sheet product Possible application examples for the use of the nonwoven sheet product are applications in the automotive sector, in particular the interior, the visible side cover of a hood of a motor vehicle, but also the use as a sandwich structure, as a filler or as the top of rotor blades in wind turbines.
  • a fiber mixture of 90% edge cut from a multiaxial fabric production and 10% bicomponent fibers based on polyester are mixed. This mixture is laid into a fleece using the carding process and cross-layer. The fleece is then consolidated under minimal pressure and at a temperature of ⁇ 200 ° C.
  • the nonwoven fabric obtained has a strength in the longitudinal direction of> 1.7 N / cm 2 , specifically with a weight per unit area of 150 g / m 2 .
  • the nonwoven fabric obtained in this way serves as fiber reinforcement for a polyester resin matrix, which is then shaped into a plate and has a 1A surface quality.
  • thermoplastic fibers are not melted or liquefied in their entirety, but only melted on in order to effect a connection or gluing with the carbon fibers.
  • the low application of pressure in the range 20 20 N / cm 2 does not lead to undesired compression of the material, but merely serves to smooth the surface of the material and to support the connection between the thermoplastic fibers and the carbon fibers. This treatment almost eliminates fiber damage.
  • the pile layer made from the fiber mixture using the carding process can be paneled in accordance with possibly desired higher grammages.
  • the fibers are glued together at temperatures of up to 200 ° C.
  • the nonwoven fabric according to the invention can be used as a flat product or as a reinforcement material for other composite materials, but can also be used as an intermediate layer or for structural reinforcement in areas where no high tensile forces are required. Due to the lack of structuring and the high fiber resolution, class A surface properties are achieved. Since there is no pressure-relevant mechanical fastening, the resulting nonwoven is an alternative to wet-bonded nonwovens.

Description

Die Erfindung betrifft ein rollfähiges textiles Vliesstoff-Flächenprodukt, bestehend aus einer Mischung von recycelten Kohlenstofffasern und thermoplastischen Fasern, welche zu einem Faserflor mittels Krempelverfahren gelegt, einer Vliesbildung unterzogen und anschließend thermisch verfestigt ist, gemäß Oberbegriff des Anspruchs 1.The invention relates to a rollable textile nonwoven sheet product, consisting of a mixture of recycled carbon fibers and thermoplastic fibers, which are laid into a fiber pile by means of a carding process, subjected to a fleece formation and then thermally bonded, according to the preamble of claim 1.

Aus der WO 2011/101094 A1 ist ein Verfahren zur Herstellung eines plattenförmigen Halbzeugs aus Faserverbundwerkstoff vorbekannt.From the WO 2011/101094 A1 a method for producing a plate-shaped semi-finished product from fiber composite material is previously known.

Der Faserverbundwerkstoff weist Fasern und wenigstens ein thermoplastisches Matrixmaterial auf. Aus faserhaltigen Abfällen oder Altteilen werden die vorerwähnten Fasern isoliert und mit thermoplastischen Fasern vermischt und in einem Krempelprozess flächig gelegt, so dass ein Faserflor erzeugt wird. In einem nachfolgenden Schritt erfolgt dann unter Wärmeeinwirkung die Ausbildung eines Plattenmaterials in Form eines Pressschritts.The fiber composite material has fibers and at least one thermoplastic matrix material. The aforementioned fibers are isolated from fiber-containing waste or old parts and mixed with thermoplastic fibers and laid flat in a carding process so that a fiber pile is produced. In a subsequent step, a plate material is formed under the action of heat in the form of a pressing step.

Es ist bekannt, Carbonfaserstoffe als hochleistungsfähige Faserstoffbewehrung einzusetzen. Anwendungen liegen hier beispielsweise im Flugzeugbau, Schiffbau, Fahrzeugbau und in Windkraftanlagen. Durch die zunehmende Anwendung derartiger Stoffe nimmt die Menge an carbonfaserhaltigen Produktionsabfällen zu. benso entstehen Abfälle ausgedienter Altteile.It is known to use carbon fibers as high-performance fiber reinforcement. Applications are here, for example, in aircraft construction, shipbuilding, vehicle construction and in wind power plants. With the increasing use of such materials, the amount of carbon fiber-containing production waste is increasing. This is how waste from used old parts is generated.

Mit der Lehre nach der WO 2011/101094 A1 wird vorgeschlagen, plattenförmige Halbzeuge aus Faserverbundwerkstoff auszubilden, wobei kostengünstig erhältliche Carbonfasern als Verstärkungsfasern einsetzbar sind. Diesbezüglich werden aus carbonfaserhaltigen Abfällen oder Altteilen Carbonfasern, Carbonfaserbündel oder deren Mischung isoliert und diese mit thermoplastischen Fremdfasern vermischt. In einem Krempelprozess erfolgt ein flächiges Ablegen und Ausrichten derart, dass ein Faserflor mit einer gezielten Orientierung der Fasern in Längsrichtung erzeugt wird. In wenigstens einem nachfolgenden Schritt wird dann die bereits erwähnte Verpressung unter Wärmeeinwirkung zu einem Plattenmaterial vorgenommen. Da sich Carbonfasern nur schwer mittels herkömmlicher Krempeltechnik verarbeiten lassen und insbesondere eine Ausrichtung in eine Vorzugsrichtung problematisch ist, wird gemäß der WO 2011/101094A1 vorgeschlagen, eine Zumengung von textilen Fremdfasern, wie z.B. Polypropylen, vorzunehmen, um den Faserorientierungsgrad auch der Carbonfasern zu erhöhen. Es werden also Hilfsfasern zur gezielten Beeinflussung des Faserorientierungsgrads von Carbonfasern ausgenutzt.With the teaching according to the WO 2011/101094 A1 it is proposed to make plate-shaped semi-finished products from fiber composite material, carbon fibers that are available at low cost can be used as reinforcing fibers. In this regard, carbon fibers, carbon fiber bundles or their mixtures are isolated from carbon fiber-containing waste or old parts and these are mixed with thermoplastic foreign fibers. In a carding process, flat laying down and alignment takes place in such a way that a fiber web is created with a targeted orientation of the fibers in the longitudinal direction. In In at least one subsequent step, the already mentioned pressing is then carried out under the action of heat to form a plate material. Since carbon fibers can only be processed with difficulty using conventional carding technology and, in particular, an alignment in a preferred direction is problematic, according to FIG WO 2011 / 101094A1 proposed adding foreign textile fibers, such as polypropylene, to increase the degree of fiber orientation of the carbon fibers as well. Auxiliary fibers are used to specifically influence the degree of fiber orientation of carbon fibers.

Die orientierten Carbonfasern werden über den Anteil thermoplastischer Fasern durch Hitze in einen klebenden Zustand verbracht mit nachfolgender Verdichtung und Verpressung zur Plattenware und schlussendlicher Abkühlung. Um die gewünschten Eigenschaften des plattenförmigen Werkstoffs zu erreichen, erfolgt das Verpressen bei einem Druck von 400 N/cm2, und zwar im Sinne einer Kompaktierung.The oriented carbon fibers are brought into an adhesive state through the proportion of thermoplastic fibers with subsequent compression and compression to form sheet goods and finally cooling. In order to achieve the desired properties of the plate-shaped material, pressing takes place at a pressure of 400 N / cm 2 , in the sense of compacting.

Ein solcher Verdichtungsprozess im Sinne eines Verpressens zum Erhalt von Plattenware führt jedoch dazu, dass die eingesetzten recycelten Kohlenstofffasern einer nicht akzeptablen Schädigung unterliegen. Trotz der hohen Presskräfte gelingt es mit dem Stand der Technik nicht, einen Verbundwerkstoff hoher Oberflächengüte zu schaffen.However, such a compression process in the sense of pressing to obtain sheet goods leads to the recycled carbon fibers used being subject to unacceptable damage. Despite the high pressing forces, the state of the art does not succeed in creating a composite material with a high surface quality.

Aus der DE 10 2013 226 921 A1 ist ein Verfahren zur Herstellung eines Vliesstoffs vorbekannt, wobei als einzige eingesetzte thermoplastische Komponente ein Faserstoff aus Polyhydroxyether Verwendung findet.From the DE 10 2013 226 921 A1 a method for producing a nonwoven fabric is previously known, the only thermoplastic component used being a fibrous material made from polyhydroxyether.

Die EP 1 772 258 B1 offenbart einen Laminataufbau eines Kunststoffteils mit groben Fasern von ≥ 10 dtex.The EP 1 772 258 B1 discloses a laminate structure of a plastic part with coarse fibers of ≥ 10 dtex.

Bekannt ist darüber hinaus ein Verfahren zur Herstellung von Verbundwerkstoffen nach der EP 0 062 142 B1 . Dabei besteht der Verbundwerkstoff aus in einer thermoplastischen Matrix eingebetteten ausgerichteten Verstärkungsfasern, wobei ein Gelege aus den ausgerichteten Verstärkungsfasern und thermoplastischem Material hergestellt und das thermoplastische Material auf eine Temperatur oberhalb seines Schmelzpunkts erwärmt wird. Als Verstärkungsfasern kommen u.a. Kohlenstofffasern in Betracht.Also known is a method for producing composite materials according to the EP 0 062 142 B1 . The composite material consists of aligned reinforcing fibers embedded in a thermoplastic matrix, a scrim made from the aligned reinforcing fibers and thermoplastic material and the thermoplastic material being heated to a temperature above its melting point. As reinforcing fibers carbon fibers come into consideration.

Die EP 2 886 693 offenbart ein rollfähiges textiles Vliesstoff-Flächenprodukt bestehend aus einer Mischung von recycelten Kohlenstofffasern und thermoplastischen Fasern, welche zu einem Faserflor mittels Krempelverfahren gelegt, einer Vliesbildung unterzogen und anschließend thermisch verfestigt ist.The EP 2,886,693 discloses a rollable textile nonwoven sheet product consisting of a mixture of recycled carbon fibers and thermoplastic fibers, which is laid into a fiber web by means of a carding process, subjected to a nonwoven formation and then thermally bonded.

Aus dem Vorgenannten ist es daher Aufgabe der Erfindung, ein weiterentwickeltes rollfähiges, d.h. aufroll- oder wickelbares textiles Vliesstoff-Flächenprodukt, bestehend aus einer Mischung aus recycelten Kohlenstofffasern und thermoplastischen Fasern, anzugeben, welches eines offenporige Vliesstruktur besitzt, so dass eine spätere weitere Behandlung, z.B. Tränkung mit einem Harz, in einfacher Weise möglich wird. Darüber hinaus soll das zu schaffende Vliesstoff-Flächenprodukt eingesetzte Kohlenstofffasern in ihrer ursprünglichen Konsistenz erhalten, d.h. es ist ein wesentliches Ziel, zum einen den Kohlenstofffaseranteil so hoch wie möglich zu halten, andererseits aber auch die erwähnten Tränkeigenschaften zu gewährleisten sowie eine Staubentwicklung durch ungebundene Faserstücke zu minimieren.From the above, it is therefore the object of the invention to provide a further developed rollable, i.e. Rollable or windable textile nonwoven sheet product, consisting of a mixture of recycled carbon fibers and thermoplastic fibers, to indicate which has an open-pore nonwoven structure, so that a later further treatment, e.g. Impregnation with a resin is possible in a simple manner. In addition, the nonwoven sheet product to be created should retain the carbon fibers used in their original consistency, i.e. One of the main goals is to keep the carbon fiber content as high as possible, but also to ensure the mentioned impregnation properties and to minimize the generation of dust from unbound fiber pieces.

Die Lösung der Aufgabe der Erfindung erfolgt durch ein rollfähiges textiles Vliesstoff-Flächenprodukt gemäß der Merkmalskombination des Anspruchs 1, wobei die Unteransprüche mindestens zweckmäßige Ausgestaltungen und Weiterbildungen umfassen.The object of the invention is achieved by means of a rollable textile nonwoven sheet product according to the combination of features of claim 1, the subclaims including at least useful embodiments and developments.

Es wird demnach von einem rollfähigen und damit leicht handhabbaren textilen Vliesstoff-Flächenprodukt ausgegangen, das aus einer Mischung von recycelten Kohlenstofffasern und thermoplastischen Fasern besteht. Diese Mischung wird zu einem Faserflor mittels Krempelverfahren gelegt, einer Vliesbildung unterzogen und anschließend thermisch verfestigt, und zwar im Sinne einer Vorverfestigung.Accordingly, a rollable and therefore easy to handle textile nonwoven sheet product is assumed, which consists of a mixture of recycled carbon fibers and thermoplastic fibers. This mixture is laid into a fiber web by means of a carding process, subjected to a fleece formation and then thermally bonded, specifically in the sense of a pre-consolidation.

Der Mischungsanteil der thermoplastischen Fasern liegt im Bereich von 5 Gew.-% bis 40 Gew.-% und der Kohlenstofffaseranteil im Bereich zwischen 60 Gew.-% und 95 Gew.-%, wobei die thermische Verfestigung zu Vermeidung von Kohlenstofffaserschäden unter niedrigem Druck von ≤ 20 N/cm2 erfolgt derart, dass die gewünschte offenporige, tränkbare Vliesstruktur erhalten bleibt.The proportion of thermoplastic fibers in the mixture is in the range from 5% by weight to 40% by weight and the proportion of carbon fibers in the range between 60% by weight and 95% by weight, the thermal bonding to avoid carbon fiber damage under low pressure of ≤ 20 N / cm 2 takes place in such a way that the desired open-pored, impregnable fleece structure is retained.

Die Faserfeinheit der eingesetzten Kohlenstofffasern liegt im Bereich ≤ 1 dtex. Die Schnittlänge der Kohlenstofffasern liegt im Bereich zwischen 30 mm und 80 mm.The fiber fineness of the carbon fibers used is in the range ≤ 1 dtex. The cut length of the carbon fibers is in the range between 30 mm and 80 mm.

Die Faserfeinheit der thermoplastischen Fasern liegt im Bereich zwischen 1,0 bis 4,0 dtex. Die Schnittlänge der thermoplastischen Fasern liegt im Bereich zwischen 30 mm und 70 mm.The fiber fineness of the thermoplastic fibers is in the range between 1.0 and 4.0 dtex. The cut length of the thermoplastic fibers is in the range between 30 mm and 70 mm.

Die Fasermischung wird einer Verfestigung durch Temperaturerhöhung im Bereich bis zu 200°C sowie anschließender Abkühlung unterzogen, wobei ein Aufschmelzen der thermoplastischen Fasern verhindert wird, jedoch die Fasern zur Verbindung mit den Kohlenstofffasern angeschmolzen werden.The fiber mixture is subjected to a solidification by increasing the temperature in the range up to 200 ° C and subsequent cooling, whereby a melting of the thermoplastic fibers is prevented, but the fibers are melted to connect with the carbon fibers.

Das erhaltene Vliesstoff-Flächenprodukt besitzt eine offenporige, gute Tränkeigenschaft, aber auch sehr gleichmäßige, eine hohe Qualität aufweisende Oberfläche.The nonwoven sheet product obtained has an open-pored, good impregnation property, but also a very uniform, high-quality surface.

Bei der Herstellung der Mischung von Kohlenstofffasern auf Recyclingbasis mit polymeren, thermoplastischen Faserstoffen wird für eine homogene Verteilung der Stoffe im Faserflor gesorgt, um eine gleichmäßige Eigenschaftsausbildung des Vlieses zu gewährleisten.During the production of the mixture of carbon fibers on a recycling basis with polymeric, thermoplastic fiber materials, a homogeneous distribution of the materials in the fiber web is ensured in order to ensure uniform properties of the fleece.

Die Kohlenstofffasern werden durch die erfindungsgemäßen Maßnahmen während des Verfestigungsprozesses nicht oder nur gering geschädigt, so dass es nicht zu einer Festigkeitsreduzierung im späteren Verbundwerkstoff sowie zu einer nachteiligen Staubentwicklung durch ungebundene Faserstücke kommt.The carbon fibers are not damaged or only slightly damaged by the measures according to the invention during the solidification process, so that there is no reduction in strength in the later composite material and disadvantageous dust generation from unbound fiber pieces.

Wie bereits dargelegt, wird der Faserflor mittels Krempelverfahren erzeugt. Der Anteil an Kohlenstofffasern wird so hoch wie möglich gewählt, da insofern der beigemischte Anteil von Thermoplasten sich als Fremdkomponente darstellt. Als thermoplastischer Faseranteil kommen Fasern aus Polyamid, Polypropylen, Polyester oder anderen Materialien, aber auch Fasern auf der Basis einer Bikomponentenstruktur, vorzugsweise aus Polyethylenterephthalat zum Einsatz. Bei einer Bikomponentenfaser ist eine der Komponenten mit einem niedrigeren Schmelzpunkt versehen als die weitere, zweite Komponente.As already explained, the fiber web is produced using a carding process. The proportion of carbon fibers is chosen as high as possible, since the added proportion of thermoplastics is a foreign component. Fibers made of polyamide, polypropylene, polyester or other materials, but also fibers based on a bicomponent structure, preferably made of polyethylene terephthalate, are used as the thermoplastic fiber content. In the case of a bicomponent fiber, one of the components has a lower melting point than the other, second component.

Die eingesetzten recycelten Kohlenstofffasern können z.B. geschnittene Rovingreste, voraufgelöste Gelege- oder Gewebereste, Randabschnitte, Fasern, die aus Kohlenstofffaser-verstärkten Kunststoffen stammen und dort mittels thermischer, chemischer oder sonstigen Aufbereitung zurückgewonnen wurden, sein.The recycled carbon fibers used can be, for example, cut roving residues, pre-dissolved scraps of scrim or fabric, edge sections, Fibers that come from carbon fiber-reinforced plastics and have been recovered there by means of thermal, chemical or other processing.

Als Verfestigungseinheit kommt ein Heißkalander, ein Glättwerk, ein Bandkalander, eine Hemdkragenpresse, eine Bandpresse oder eine Heißmangel zum Einsatz, wobei eine Modifikation derartig erfolgt, dass der aufgebrachte Druck im Bereich ≤ 2 bar, d.h. ≤ 20 N/cm2 liegt, um Faserschädigungen auf jeden Fall zu vermeiden.A hot calender, a smoothing unit, a belt calender, a shirt collar press, a belt press or a hot ironer are used as the consolidation unit, whereby a modification is made such that the pressure applied is in the range ≤ 2 bar, i.e. ≤ 20 N / cm 2 , to avoid fiber damage definitely to avoid.

Darüber hinaus werden im Vergleich zum Stand der Technik keine Prägemuster auf dem erhaltenen Material aufgebracht.Furthermore, in comparison with the prior art, no embossing patterns are applied to the material obtained.

Die entstandene Ware wird erfindungsgemäß spannungsarm und schonend mittels eines Steigdockenwicklers aufgewickelt.According to the invention, the resulting goods are wound up gently and with little tension by means of an ascending batch winder.

Das Gewicht des erhaltenen Vliesstoffs liegt im Bereich von 50 bis 200 g/m2, vorzugsweise im Bereich zwischen 80 bis 150 g/m2.The weight of the nonwoven fabric obtained is in the range from 50 to 200 g / m 2 , preferably in the range between 80 to 150 g / m 2 .

Die Festigkeitseigenschaften des Vliesstoff-Flächenprodukts sind im Vergleich zum Flächengewicht gering, allerdings weit mehr als ausreichend, um sowohl das gewünschte Aufwickeln als auch ein positives Handling bei der späteren Verarbeitung zu gewährleisten.The strength properties of the nonwoven sheet product are low compared to the weight per unit area, but far more than sufficient to ensure both the desired winding and positive handling during subsequent processing.

In Ausgestaltung der Erfindung können zusätzlich zum Kohlenstofffaseranteil weitere Komponenten an Hochleistungsfaserstoffen aus Recyclingprozessen eingemischt werden. Hier kann es sich beispielsweise um Aramidfasern, Glasfasern, Basaltfasern oder dergleichen handeln. Es ist jedoch dafür Sorge zu tragen, dass der Anteil an thermoplastischen Fasern von 5 Gew.-% bis maximal 40 Gew.-% beibehalten und nicht überschritten wird.In an embodiment of the invention, further components of high-performance fibers from recycling processes can be mixed in in addition to the carbon fiber content. This can be, for example, aramid fibers, glass fibers, basalt fibers or the like. However, care must be taken to ensure that the proportion of thermoplastic fibers of 5% by weight to a maximum of 40% by weight is maintained and not exceeded.

Zur Veränderung und Optimierung der Materialeigenschaften kann eine Nassausrüstung mit chemischen Substanzen auf dem Material vorgenommen werden, wobei mittels eines Trocknungs- und Fixierungsprozesses dann ein Ausreagieren dieser Substanzen erfolgt.In order to change and optimize the material properties, the material can be wet-finished with chemical substances, with these substances then reacting out by means of a drying and fixing process.

Das Vliesstoff-Flächenprodukt kann mit Harz vorimprägniert werden, um so ein Prepreg zu erhalten.The nonwoven sheet product can be pre-impregnated with resin to obtain a prepreg.

Mögliche Anwendungsbeispiele zur Nutzung des Vliesstoff-Flächenprodukts sind Einsatzfälle im Bereich des Kraftfahrzeugsektors, insbesondere des Interiors, die Sichtseitenabdeckung einer Motorhaube eines Kraftfahrzeugs, aber auch die Nutzung als Sandwichaufbau, als Füllstoff oder als Oberseite von Rotorblättern in Windkraftanlagen.Possible application examples for the use of the nonwoven sheet product are applications in the automotive sector, in particular the interior, the visible side cover of a hood of a motor vehicle, but also the use as a sandwich structure, as a filler or as the top of rotor blades in wind turbines.

Die Erfindung soll nachstehend anhand eines Ausführungsbeispiels näher erläutert werden.The invention is to be explained in more detail below using an exemplary embodiment.

Eine Fasermischung aus 90% Randschnitt einer Multiaxialgelegeproduktion und 10 % Bikomponentenfasern auf Basis von Polyester werden vermischt. Diese Mischung wird mittels Krempelverfahren und Querleger zu einem Vlies gelegt. Anschließend wird das Vlies unter minimaler Druckeinwirkung und bei einer Temperatur < 200°C verfestigt. Der erhaltene Vliesstoff weist eine Festigkeit in Längsrichtung von > 1,7 N/cm2 auf, und zwar bei einem Flächengewicht von 150 g/m2. Der so erhaltene Vliesstoff dient als Faserverstärkung für eine Polyesterharzmatrix, welche dann zu einer Platte geformt eine 1A-Oberflächenqualität aufweist.A fiber mixture of 90% edge cut from a multiaxial fabric production and 10% bicomponent fibers based on polyester are mixed. This mixture is laid into a fleece using the carding process and cross-layer. The fleece is then consolidated under minimal pressure and at a temperature of <200 ° C. The nonwoven fabric obtained has a strength in the longitudinal direction of> 1.7 N / cm 2 , specifically with a weight per unit area of 150 g / m 2 . The nonwoven fabric obtained in this way serves as fiber reinforcement for a polyester resin matrix, which is then shaped into a plate and has a 1A surface quality.

Bei dieser Behandlung werden die thermoplastischen Fasern nicht zur Gänze aufgeschmolzen oder verflüssigt, sondern lediglich angeschmolzen, um eine Verbindung bzw. Verklebung mit den Kohlenstofffasern zu bewirken.In this treatment, the thermoplastic fibers are not melted or liquefied in their entirety, but only melted on in order to effect a connection or gluing with the carbon fibers.

Die niedrige Druckanwendung im Bereich ≤ 20 N/cm2 führt nicht zu einer unerwünschten Verdichtung des Materials, sondern dient lediglich dazu, die Oberfläche des Materials zu glätten und die Verbindung zwischen den thermoplastischen Fasern und den Kohlenstofffasern zu unterstützen. Eine Faserschädigung wird durch diese Behandlung nahezu ausgeschlossen.The low application of pressure in the range 20 20 N / cm 2 does not lead to undesired compression of the material, but merely serves to smooth the surface of the material and to support the connection between the thermoplastic fibers and the carbon fibers. This treatment almost eliminates fiber damage.

Die Florlage aus der Fasermischung unter Nutzung des Krempelverfahrens kann entsprechend möglicherweise gewünschter höherer Flächengewichte getäfelt werden. Die Verklebung der Fasern untereinander geschieht bei Temperaturen von bis zu 200°C.The pile layer made from the fiber mixture using the carding process can be paneled in accordance with possibly desired higher grammages. The fibers are glued together at temperatures of up to 200 ° C.

Der erfindungsgemäße Vliesstoff kann als Flächenprodukt oder als Verstärkungsmaterial für sonstige Verbundwerkstoffe Verwendung finden, aber auch als Zwischenlage oder zur Strukturverstärkung in solchen Bereichen eingesetzt werden, wo keine Hochzugkräfte benötigt werden. Aufgrund der fehlenden Strukturierung und der hohen Faserauflösung werden Klasse A-Oberflächeneigenschaften erreicht. Da keine druckrelevante mechanische Befestigung vorliegt, stellt sich der erhaltene Vliesstoff als eine Alternativ zu nassverfestigten Vliesstoffen dar.The nonwoven fabric according to the invention can be used as a flat product or as a reinforcement material for other composite materials, but can also be used as an intermediate layer or for structural reinforcement in areas where no high tensile forces are required. Due to the lack of structuring and the high fiber resolution, class A surface properties are achieved. Since there is no pressure-relevant mechanical fastening, the resulting nonwoven is an alternative to wet-bonded nonwovens.

Claims (8)

  1. A textile nonwoven sheet product which is capable of rolling, consisting of a mixture of recycled carbon fibers and thermoplastic fibers, which mixture is laid to a fibrous web by means of a carding process, is subjected to fleece formation and subsequently thermally bonded, wherein the mixing proportion of the thermoplastic fibers is in the range of 5 % by weight to 40 % by weight, and the carbon fiber proportion is in the range between 60 % by weight and 95 % by weight, characterized in that,
    for avoiding carbon fiber damages, the thermal bonding is performed under a low pressure of ≤ 20 N/cm2 such that an impregnable fleece structure with open pores is the result, wherein the fiber fineness of the individual carbon fibers is in the range of ≤ 1 dtex and the cutting length is 30 mm to 80 mm as well as the fiber fineness of the thermoplastic single fibers is in the range between 1.0 dtex to 4.0 dtex and the cutting length is 30 mm to 70 mm.
  2. The nonwoven sheet product according to claim 1,
    characterized in that
    the fiber mixture is subjected to bonding by a temperature increase up to 200°C and subsequent cooling, wherein fusing of the thermoplastic fibers is avoided.
  3. The nonwoven sheet product according to any one of the preceding claims,
    characterized in that
    the fleece layer is paneled for achieving higher surface weights.
  4. The nonwoven sheet product according to any one of the preceding claims,
    characterized in that
    the treatment under low pressure causes the material surface to be smoothed without disadvantageous compaction.
  5. The nonwoven sheet product according to any one of the preceding claims,
    characterized in that
    it is formed as a fiber reinforcement for a polymer resin matrix.
  6. The nonwoven sheet product according to any one of the preceding claims,
    characterized in that
    the mixture contains further high-performance fiber materials such as aramid fibers, glass fibers and/or basalt fibers.
  7. The nonwoven sheet product according to any one of the preceding claims,
    characterized in that
    the obtained open-pored fleece structure has a resin pre-impregnation.
  8. The nonwoven sheet product according to any one of the preceding claims,
    characterized in that
    it is formed as an interior component in the automotive sector.
EP17721088.7A 2016-05-04 2017-04-27 Textile nonwoven sheet product which is capable of rolling Active EP3452651B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE202016002901 2016-05-04
DE202016003587.9U DE202016003587U1 (en) 2016-05-04 2016-06-07 Rollable textile nonwoven surface product
PCT/EP2017/060000 WO2017191024A1 (en) 2016-05-04 2017-04-27 Textile nonwoven sheet product which is capable of rolling

Publications (2)

Publication Number Publication Date
EP3452651A1 EP3452651A1 (en) 2019-03-13
EP3452651B1 true EP3452651B1 (en) 2020-10-14

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EP17721088.7A Active EP3452651B1 (en) 2016-05-04 2017-04-27 Textile nonwoven sheet product which is capable of rolling

Country Status (3)

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EP (1) EP3452651B1 (en)
DE (1) DE202016003587U1 (en)
WO (1) WO2017191024A1 (en)

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3113930A1 (en) 1981-04-07 1982-10-28 Messerschmitt-Bölkow-Blohm GmbH, 8000 München METHOD FOR THE PRODUCTION OF FABRICS FOR THERMOPLASTIC COMPOSITIONS WITH ALIGNED REINFORCING FIBERS
DE102005048603A1 (en) 2005-10-06 2007-04-26 J.H. Ziegler Gmbh & Co. Kg Non-woven plastic laminate infiltratable for the production of fiber-reinforced plastic parts
ES2395992T3 (en) * 2007-06-01 2013-02-18 Formfiber Denmark Aps A product of nonwoven fibers consolidated by air flow comprising recycled material fibers
DE102010008370A1 (en) 2010-02-17 2011-08-18 Thüringisches Institut für Textil- und Kunststoff-Forschung e.V., 07407 Process for producing a plate-shaped semifinished product made of fiber composite material
ITRM20120118A1 (en) * 2012-03-26 2013-09-27 Agenzia Naz Per Le Nuove Tecn Ologie L Ener METHOD FOR THE REALIZATION OF FELT FROM RECYCLING CARBON FIBER.
DE102013226921A1 (en) 2013-12-20 2015-06-25 Sgl Automotive Carbon Fibers Gmbh & Co. Kg Nonwoven fabric made of carbon fibers and thermoplastic fibers

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
None *

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EP3452651A1 (en) 2019-03-13
DE202016003587U1 (en) 2016-06-23

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