Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
  • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
  • C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
  • C08J5/244—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using glass fibres
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
  • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
  • C08J5/0405—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
  • C08J5/043—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres with glass fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
  • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
  • B29B15/10—Coating or impregnating independently of the moulding or shaping step
  • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
  • B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
• • 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]
  • B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
  • B29C70/521—Pultrusion, i.e. forming and compressing by continuously pulling through a die and impregnating the reinforcement before the die
  • B29C70/522—Pultrusion, i.e. forming and compressing by continuously pulling through a die and impregnating the reinforcement before the die the transport direction being vertical
• • 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]
  • B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
  • B29C70/523—Pultrusion, i.e. forming and compressing by continuously pulling through a die and impregnating the reinforcement in the die
• • 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]
  • B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
  • B29C70/525—Component parts, details or accessories; Auxiliary operations
  • B29C70/526—Pultrusion dies, e.g. dies with moving or rotating parts
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
  • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2300/00—Characterised by the use of unspecified polymers
  • C08J2300/22—Thermoplastic resins
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2371/00—Characterised by the use of polyethers obtained by reactions forming an ether link in the main chain; Derivatives of such polymers
  • C08J2371/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
  • C08J2371/10—Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
  • C08J2371/12—Polyphenylene oxides
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2377/00—Characterised by the use of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Derivatives of such polymers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2377/00—Characterised by the use of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Derivatives of such polymers
  • C08J2377/06—Polyamides derived from polyamines and polycarboxylic acids
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2379/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen with or without oxygen, or carbon only, not provided for in groups C08J2361/00 - C08J2377/00
  • C08J2379/02—Polyamines

Definitions

• TITLE PROCESS FOR THE PREPARATION OF A FIBROUS MATERIAL IMPREGNATED BY REACTIVE PULTRUSION [Technical field]
• the present invention relates to a process for preparing a fibrous material impregnated with a thermoplastic polymer by reactive pultrusion, the tapes obtained by the process and their use.
• the impregnation resin is a non-reactive or slightly reactive polymer of sufficiently low viscosity ( ⁇ 100 Pa.s) to be able to impregnate the strands of fibers (rovings) at a line speed of between 0.2 to lm / min while keeping a reasonable head length so as to limit the friction surface on the rovings as well as the machining cost.
• the impregnation of a roving can be characterized by a diffusion time of the resin in the heart of the roving. This diffusion time is a function of several factors such as the viscosity of the thermoplastic polymer, the speed of the line and the thickness of the roving.
• bindings In impregnation techniques, the use of bindings is known to reduce the diffusion time of the resin through the roving and to homogenize the distribution of the fibers by going from a roving of circular section to a rectangular section of ratio. very high width / thickness (large width, low thickness).
• the jams can be upstream of the sector and / or inside the sector.
• the upstream jams have the role of expanding the roving and the jams inside the die make it possible to generate a roving / solid contact zone.
• international application WO2013086258 describes the impregnation of a fibrous material with a non-reactive thermoplastic polymer by passing a wick or roving through an impregnation zone in the pultrusion head in a channel in which the thermoplastic polymer is injected. at the entrance to the channel on one of the surfaces of said wick to obtain an asymmetric impregnated fibrous material, that is to say that the impregnated fibrous material has a portion rich in fiber and a portion rich in thermoplastic polymer in the direction of the thickness.
• Each channel present in the pultrusion head is equipped with several contact surfaces allowing the friction of the wick so as to reduce the diffusion time of the thermoplastic polymer through the roving.
• the maximum tensile force that the wicks can withstand ranges from 1000 to 15000 MPa for wicks having a mass per unit length of 0.05 to 2g / m.
• the viscosity in the state melt of the thermoplastic polymer used is from 25 to 50,000 Pa.s. It is of course understood by those skilled in the art that such high viscosities do not make it possible to impregnate in sufficiently rapid times and / or over sufficiently large thicknesses to be of any interest from an industrial point of view.
• this roving at any time during its journey is included in the volume of the channel, composed of the volume of the roving and a free volume. Without this free volume, the fiber would occupy the entire volume of the canal, leading to very significant friction on the walls and the premature rupture of the rovings. It is therefore this free volume, necessary for the process, which generates a residence time of the resin in the head but said residence time must be limited to the maximum while still allowing the diffusion of the polymer.
• thermoplastic in the roving and not have too much viscosification of the resin before impregnation which would prevent impregnation or block the pultrusion head.
• the latter when a mixture of prepolymers is used for the polymerization, the latter must be sufficiently fluid to be able to impregnate the fibers with this reactive mixture. It is therefore necessary to heat at high temperature to carry out the impregnation, in particular when the Tg of the prepolymers is high, but then the polymerization reaction then becomes too rapid and the viscosification prevents the correct impregnation of the fibers.
• the invention therefore relates to a method of manufacturing at least one impregnated fibrous material comprising a fibrous material in continuous fibers and at least one thermoplastic polymer with a glass transition temperature Tg greater than or equal to 40 ° C, in particular greater than or equal to 80 ° C, preferably from 100 to 200 ° C, more preferably from 110 to 200 ° C, or a melting temperature Tf less than or equal to 400 ° C, in particular less than or equal to 350 ° C, in particular less or equal to 290 ° C,
• thermoplastic polymer comprising at least one precursor of said thermoplastic polymer in the presence of said fibrous material
• said at least one fibrous material being during its entry into said pultrusion head divided in its thickness into n layers, in particular of substantially equal thicknesses, n being comprised from 2 to 20, in particular from 2 to 10, more particularly from 2 to 5, in particular equal to 4,
• the injection of said reactive composition being carried out in each channel and / or between said layers during their reunification at the outlet of each channel, said channel being heated to a temperature such that the reactive composition has an initial viscosity in the molten state of less than 50 Pa.s, more preferably less than 20 Pa.s, even more preferably less than 10 Pa.s, in particular less than 5 Pa.s, the impregnation starting at the time of injection and ending before or after the reunification of said layers by superposition to form said at least one final impregnated fibrous material in which said precursors of said thermoplastic polymer are at least partially polymerized.
• the inventors have unexpectedly found that dividing the thickness of a fibrous material to be impregnated with a reactive composition, into several layers, in particular of substantially equal thickness, each layer circulating in a channel heated to a temperature such that the reactive composition which comprises precursors (also called reactive oligomers or also called reactive prepolymers) of low starting or initial viscosity in the molten state ( ⁇ 50 Pa.s) and which will impregnate said layers made it possible to reduce to a minimum the diffusion time of the reactive composition in said layers and therefore of impregnating said layers before or after their reunification while carrying out the polymerization at least partially.
• precursors also called reactive oligomers or also called reactive prepolymers
• the process of the invention makes it possible to ensure the double constraint which is to raise the initial viscosity sufficiently to have molar masses (Mn) of the polymer sufficiently high so as to have good mechanical strength and " controlling »this rise in viscosity / mass so as to ensure impregnation before the viscosity becomes too high.
• This process also makes it possible to minimize the dead volume in each channel.
• This process therefore makes it possible to achieve line speeds greater than 1 m / min and thus significantly reduce the manufacturing costs of pultruded profiles.
• the reactivity of the oligomers makes it possible, after complete polymerization, to achieve mechanical properties that are much higher than what is obtained in traditional pultrusion, at equivalent impregnation quality.
• the glass transition temperature Tg and the melting temperature Tf are measured in DSC according to ISO 11357-2: 2013 and ISO 11357-3: 2013.
• the viscosity in the molten state is measured by oscillatory rheology at a temperature Tf ⁇ T ⁇ Tf + 50 ° C for a semi-crystalline polymer or Tg + 220 ° C for an amorphous polymer, at 10 rad / sec under sweeping of nitrogen with 5% deformation on a Physica MCR301 apparatus between two parallel planes 25 mm in diameter.
• a semi-crystalline polymer within the meaning of the invention, denotes a polymer which exhibits a
• Tf melting temperature in DSC according to standard ISO 11357-3: 2013, and an enthalpy of crystallization during the cooling step at a speed of 20K / min in DSC measured according to standard ISO 11357-3 of 2013 higher or equal to 30 J / g, preferably greater than or equal to 35 J / g.
• An amorphous polymer within the meaning of the invention, denotes a polymer exhibiting only a glass transition temperature (no melting point (Tm)) in DSC according to the ISO 11357-2: 2013 standard, or a very low crystalline polyamide having a glass transition temperature in DSC according to ISO 11357-2: 2013 and a melting point such as the enthalpy of crystallization during the cooling step at a speed of 20K / min in differential scanning calorimetry ("Differential Scanning Calorimetry »DSC) measured according to the ISO 11357-3: 2013 standard is less than 30 J / g, in particular less than 20 J / g, preferably less than 15 J / g.
• each layer after separation of the fibrous material (or wick) has a thickness e ⁇ 25%, in particular ⁇ 12%.
• Each layer circulates in its own channel, so there is only one layer per channel and therefore there cannot be two or more layers per channel.
• reactive composition means that the molecular weight of said reactive composition (or its viscosity in the molten state) will change during the use by reaction of prepolymers (or oligomers) reactive with themselves or with each other by condensation or with a chain extender by polyaddition and without elimination of volatile by-products to lead, after polymerization or by complete nucleophilic substitution, to the final polyamide polymer of the thermoplastic matrix.
• said reactive prepolymers are prepared by conventional polycondensation reaction between the corresponding diamine and diacid components and optionally amino acids or lactams.
• the prepolymers bearing X and Y amine and carboxy functions on the same chain can be obtained for example by adding a combination of monomers (amino acid, diamine, diacid) having in total an equal amount of amine and carboxy units.
• said at least partially polymerized reactive thermoplastic prepolymer comprises at least one reactive prepolymer (in particular polyamide) carrying, on the same chain (that is to say on the same prepolymer), two terminal functions X 'and Y 'functions respectively coreactive with each other by condensation, with X' and Y 'being amine and carboxy or carboxy and amine respectively.
• said at least partially polymerized reactive thermoplastic prepolymer consists of at least one reactive prepolymer (in particular polyamide) carrying on the same chain (that is to say on the same prepolymer), of two terminal functions X 'and Y 'functions respectively coreactive with each other by condensation, with X' and Y 'being amine and carboxy or carboxy and amine respectively.
• said at least partially polymerized reactive thermoplastic prepolymer comprises at least two polyamide prepolymers reactive with each other and each carrying respectively two terminal functions X 'or Y', identical (identical for the same prepolymer and different between the two prepolymers), said X 'function of a prepolymer being able to react only with said Y' function of the other prepolymer, in particular by condensation, more particularly with X 'and Y' being amine and carboxy or carboxy and amine respectively.
• said at least partially polymerized reactive thermoplastic prepolymer consists of at least two polyamide prepolymers which are reactive with each other and with each carrier.
• the at least two prepolymers may or may not be mixed together beforehand.
• This condensation (or polycondensation) reaction can cause the appearance of by-products.
• the reaction of the two prepolymers can be total or partial.
• said at least reactive thermoplastic prepolymer partially polymerized with the chain extender comprises:
• n n terminal reactive functions X, identical chosen from: -NH2 (amine), - C02H (carboxy) and -OH (hydroxyl), preferably - NH2 (amine) and -CO2H (carboxy), with n being 1 to 3, preferably 1 to 2, more preferably 1 or 2, more particularly 2
• a2) at least one Y-A'-Y chain extender, with A 'being a hydrocarbon-based biradical, carrying 2 identical terminal reactive functions Y, reactive by polyaddition (without elimination of reaction by-product), with at least one function X of said prepolymer a1), preferably of molecular mass less than 500 and more preferably less than 400.
• said at least reactive thermoplastic prepolymer partially polymerized with the chain extender consists of a1) and a2) defined above.
• Y is chosen from: oxazine, oxazoline, oxazolinone, oxazinone, imidazoline, epoxy, isocyanate, maleimide, cyclic anhydride, in particular oxazine, oxazoline, oxazolinone, oxazinone, imidazoline, maleimide, cyclic anhydride and preferably XI is C02H and Y1 is chosen from an epoxy and an oxazoline.
• NH2 (amine) stands for primary and secondary amine.
• extenders a2) as a function of the X functions carried by said semi-crystalline polyamide prepolymer a1), the following may be mentioned:
• Y chosen from the groups: maleimide, optionally blocked isocyanate, oxazinone and oxazolinone, cyclic anhydride, preferably oxazinone and oxazolinone, in particular maleimide, oxazinone and oxazolinone, cyclic anhydride, preferably oxazinone and oxazolinone
• cycloaliphatic the latter two comprising at least one ring of 5 or 6 carbon atoms optionally substituted, optionally with said aliphatic hydrocarbon chain optionally having a molecular weight of 14 to 200 g.mol-1
• either the chain extender Y-A'-Y corresponds to Y being a caprolactam group and to A 'which may be a carbonyl radical such as carbonyl biscaprolactam or to A' which may be a terephthaloyl or an isophthaloyl,
• either said chain extender Y-A'-Y carries a cyclic anhydride group Y and preferably this extender is chosen from a cycloaliphatic and / or aromatic dianhydride carboxylic and more preferably it is chosen from: ethylenetetracarboxylic dianhydride, pyromellitic dianhydride , 3,3 ', 4,4'-biphenyltetracarboxylic dianhydride, 1, 4,5,8-naphthalenetetracarboxylic dianhydride, perylenetetracarboxylic dianhydride, 3, 3', 4,4'-benzophenone tetracarboxylic, dianhydride 1, 2,3,4-cyclobutanetetracarboxylic, hexafluoroisopropylidene bisphthalic dianhydride, 9,9-bis (trifluoromethyl) xanthenetetracarboxylic dianhydride, 3, 3 ', 4,4'-dipheny
• said Y-A'-Y chain extender corresponds to:
• Y chosen from the groups: oxazoline, oxazine, imidazoline or aziridine, such as 1, l'-iso- or tere-phthaloyl-bis (2-methyl aziridine) or epoxy,
• a ' being a spacer or a carbon radical as defined above.
• said function Y is chosen from oxazinone, oxazolinone, oxazine, oxazoline or imidazoline, in particular oxazoline
• a ' can represent an alkylene such as - (CH2) m- with m ranging from 1 to 14 and preferably from 2 to 10 or
• A' can represent a cycloalkylene and / or a substituted (alkyl) or unsubstituted arylene , such as benzene arylenes, such as o-, m-, -p phenylenes or naphthalene arylenes and preferably
• a ′ is an arylene and / or a cycloalkylene.
• the chain extender can be chosen from bisphenol A diglycidyl ether (DGEBA), and its hydrogenated derivative (cycloaliphatic) bisphenol F diglycidyl ether, tetrabromo bisphenol A diglycidyl ether, or hydroquinone diglycidyl ether, ethylene glycol diglycidyl ether, propylene glycol diglycidyl ether, butylene glycol diglycidyl ether, neopentyl glycol diglycidyl ether, 1,4- butanediol diglycidyl ether, 1,6-hexanediol diglycidyl ether, cyclohexanedimethanol diglycidyl ether diglycidyl ether, polyethylene glycol ⁇ 500 , polypropylene glycol diglycidyl ether of Mn ⁇ 500, polytetramethylene glycol diglycidyl ether of Mn ⁇ 500,
• DGEBA bisphenol A dig
• polypropylene glycol diglycidyl ether of Mn ⁇ 500 diglycidyl esters of dicarboxylic acid such as the glycidyl ester of terephthalic acid or epoxidized diolefins (dienes) or epoxidized double ethylenically unsaturated fatty acids, diglycidyl 1,2-Cyclohexanedicarboxylate and mixtures thereof.
• this blocking can be obtained by blocking agents of the isocyanate function, such as epsilon-caprolactam, methyl ethyl ketoxime, dimethyl pyrazole, diethyl malonate.
• blocking agents of the isocyanate function such as epsilon-caprolactam, methyl ethyl ketoxime, dimethyl pyrazole, diethyl malonate.
• the preferred conditions avoid any formation of an imide ring during the polymerization and during the processing in the state.
• the Y group is preferably chosen from: isocyanate (unblocked), oxazinone and oxazolinone, more preferably oxazinone and oxazolinone, with as spacer or hydrocarbon radical A ′ being as defined above.
• chain extenders carrying reactive Y oxazoline or oxazine functions suitable for the implementation of the invention, reference may be made to those described under references “A”, “B”, “C” and “D”. on page 7 of application EP 0 581 642, as well as their methods of
• A in this document is bisoxazoline
• B is bisoxazine
• C is 1,3 phenylene bisoxazoline
• D is 1,4-phenylene bisoxazoline.
• the reaction product obtained has at least one repeating unit of the following structure: - 0-C (0) -PC (0) -0-Rl-NH-C (0) -A'-C (0) -NH-Rl- in which:
• P is a polyamide containing H0-C (0) -P-C (0) -0H acid terminations obtained from the amide units (A), (B) or (C),
• chain extenders with a reactive Y imidazoline function suitable for implementing the invention, reference may be made to those described (“A” to “F”) on page 7 to 8 and Table 1 of the invention. page 10 in application EP 0 739 924 as well as to their preparation processes and their reaction modes which are set out therein.
• chain extenders with a reactive function Y oxazinone or oxazolinone which are suitable for the implementation of the invention, reference may be made to those described under references “A” to "D” on page 7 to 8 of application EP 0 581 641, as well as to their preparation processes and their reaction modes which are described therein.
• Suitable oxazinone (6-atom ring) and oxazolinone (5-atom ring) Y groups mention may be made of the Y groups derived from: benzoxazinone, oxazinone or
• oxazolinone with the spacer A 'possibly being a single covalent bond with the respective corresponding extenders being: bis- (benzoxazinone), bisoxazinone and bisoxazolinone.
• the radical A ' can be as described above with A' possibly being a single covalent bond and with the extenders respective correspondents being: bisoxazine, bisoxazoline and bisimidazoline.
• Oh maybe also C1 to C14, preferably C2 to C10 alkylene.
• the radical A ' is preferably an arylene and, more particularly, it can be a phenylene (substituted by Y in positions 1,2 or 1,3 or 1,4) or a naphthalene radical (disubstituted by Y) or a phthaloyl ( iso- or terephthaloyl) or A 'can be cycloalkylene.
• the radical A ' can be a phthaloyl (1,1'iso- or terephthaloyl) with as an example of an extender of this type 1, isophthaloyl-bis (2-methyl aziridine).
• a catalyst for the reaction between said prepolymer P (X) n and said extender Y-A'-Y at a rate ranging from 0.001 to 2%, preferably from 0.01 to 0.5% relative to total weight of the two co-reactants mentioned can accelerate the (poly) addition reaction and thus shorten the production cycle.
• Such a catalyst can be chosen from: 4,4 'dimethyl aminopyridine, p-toluenesulphonic acid, phosphoric acid, NaOH and optionally those described for a polycondensation or
• a ′ may represent an alkylene, such as - (CH 2) m- with m ranging from 1 to 14 and preferably from 2 to 10 or represents an alkyl substituted or unsubstituted arylene, such as benzene arylenes (such as o-, m-, -p phenylenes) or
• a ′ represents an arylene which may or may not be substituted benzene or naphthenic.
• said chain extender (a2) preferably has a molecular mass of less than 500, more preferably less than 400.
• the said extender rate used varies from 1 to 20%, in particular from 5 to 20%, in particular from 10 to 20% by weight.
• said reactive prepolymers are prepared by conventional polycondensation reaction between the corresponding diamine and diacid components and optionally amino acids or lactams.
• the prepolymers bearing X 'and Y' amine and carboxy functions on the same chain can be obtained for example by adding a combination of monomers (amino acid, diamine, diacid) having in total an equal amount of amine and carboxy units.
• n 2 functionality can be obtained from difunctional components: diamines and diacids with excess of one to fix XI depending on this excess.
• n 3 for example, for a prepolymer P (Xl) n, a component must be present
• thermoplastic prepolymer or mixture of prepolymers are thermoplastic prepolymer or mixture of prepolymers
• thermoplastics further comprises carbonaceous fillers, in particular carbon black or carbon nanofibrils, preferably chosen from carbonaceous nanofillers, in particular graphenes and / or carbon nanotubes and / or carbon nanofibrils or their mixtures. These charges allow electricity and heat to be conducted, and therefore facilitate the melting of the prepolymer matrix when it is heated.
• carbonaceous fillers in particular carbon black or carbon nanofibrils, preferably chosen from carbonaceous nanofillers, in particular graphenes and / or carbon nanotubes and / or carbon nanofibrils or their mixtures.
• the number average molecular weight Mn of said final thermoplastic polymer is preferably in a range of 10,000 to 40,000, preferably 12,000 to 30,000 determined in particular by calculation from the level of terminal functions determined by potentiometric titration in solution and the functionality of said prepolymers.
• the Mn masses can also be determined by size exclusion chromatography or by NMR.
• Mn values may correspond to inherent viscosities greater than or equal to 0.8 as determined in m-cresol according to standard ISO 307: 2007 but by changing the solvent (use of m-cresol instead of sulfuric acid and the temperature being 20 ° C).
• Said precursor prepolymers have a number-average molecular mass Mn ranging from 500 to 10,000, preferably from 1000 to 6000, in particular from 2500 to 6000.
• said reactive composition comprises or consists of:
• thermoplastic polymer - 50 to 100% by weight of at least one precursor of said thermoplastic polymer
• thermoplastic polymer - 0 to 50% by weight of at least one additive and / or at least one other thermoplastic polymer
• the additives can be chosen from, without being limited to these, specific additives capable of absorbing at the wavelength of a laser, such as for example a UV or IR laser, this allowing the use of the placement technology.
• automatic fibers AFP
• Other additives such as thermal stabilizers can be added to the precursor composition and therefore be present in the material final thermoplastic composite as used in the final application parts, in particular these stabilizers being antioxidants, against thermo-oxidation and / or photo-oxidation of the polymer of the thermoplastic matrix.
• Said antioxidants are of the sterically hindered phenolic and / or sterically hindered amine type (known under the common name HALS).
• HALS sterically hindered phenolic and / or sterically hindered amine type
• N + PE masterbatch with about 40% of CN include the EUTHYLEN ® marketed by BASF.
• NC + PA masterbatch with about 15% of NC include RENOL BLACK ® marketed by Clariance.
• the additives can also be fillers which, in addition to long reinforcing fibers, can in particular be any filler known to those skilled in the art in the field of composites. They may in particular be charges which conduct heat and / or conduct electricity, such as metal powder, powdery carbon black, carbon fibrils, carbon nanotubes (CNTs) or carbide. of silicon, boron carbonitride, boron nitride or silicon. Reference may be made on this subject to application WO 2010/130930 by the Applicant.
• the additives can also be flame retardants, such as a metal salt chosen from a metal salt of phosphinic acid, a metal salt of diphosphinic acid, a polymer containing at least one metal salt of phosphinic acid, a polymer containing at least one metal salt of diphosphinic acid.
• thermoplastic polymer denotes any non-reactive thermoplastic polymer and in particular a polyamide polymer, in particular an aliphatic, cycloaliphatic or aromatic polyamide, and which may be semi-crystalline or amorphous.
• non-reactive thermoplastic polymer a polymer whose molecular weight is no longer likely to change significantly, that is to say that its molecular weight in number (Mn) changes by less than 50% during its Implementation.
• the injection of said reactive composition is carried out in each channel, at a position which may be at the inlet of each channel, at the outlet of each channel or between the inlet and the outlet of each channel (in the latter case, there may be one or more injection points) and / or between said layers when they leave each channel.
• the injection is carried out between said layers when they leave each channel.
• the injection of said reactive composition is carried out between two layers, two by two, at the outlet of said channels, said two layers then being impregnated to form an impregnated bilayer material, each impregnated bilayer material then being assembled in its thickness with the others to form said final impregnated fibrous material.
• the injection is performed at the inlet of each channel.
• the injection is performed at the inlet of each channel and between said layers when they leave each channel.
• the injection is carried out at the inlet of each channel and between the inlet and the outlet of each channel.
• the injection is performed between the inlet and the outlet of each channel and between said layers when they leave each channel.
• the injection is performed at the input of each channel and between the input and the output of each channel and between said layers when they leave each channel.
• the fibrous material consists of a set of rovings which can be up to several thousand.
• the fibrous material before impregnation, is during its entry into said pultrusion head divided in its thickness into n layers. It is quite evident that at least one fibrous material enters the pultrusion head and therefore, when several fibrous materials enter the pultrusion head, each fibrous material is divided in its thickness into n layers.
• the constituents of the reactive composition are mixed in a supply channel, at the inlet or at the outlet of said channel.
• the channels are heated to a temperature such that the reactive composition has an initial viscosity in the molten state of less than 50 Pa.s, more preferably less than 20 Pa.s, even more preferably less than 10 Pa.s, in particular less than 5 Pa.s.
• the initial viscosity means the viscosity at the time t of mixing in the supply channel of said reactive composition, that is to say that when the reactive composition is introduced into the supply channel, the initial viscosity of said reactive composition is less than 50 Pa.s, more preferably less than 20 Pa.s, even more preferably less than 10 Pa.s, in particular less than 5 Pa.s, or when said reactive composition is introduced between said layers at the outlet of each channel, each layer having circulated in a channel which is heated, said layer is then itself at the temperature of said channel and the initial viscosity of said reactive composition is also less than 50 Pa.s, more preferably less than 20 Pa.s , even more preferably less than 10 Pa.s, in particular less than 5 Pa.s.
• the low viscosity during the injection of said reactive composition allows rapid impregnation of said layer with said reactive composition.
• the impregnation begins at the time of injection and the polymerization of said reactive composition begins as soon as the constituents are mixed, ie a little time before the start of the impregnation.
• Impregnation and at least partial polymerization are therefore concomitant in the process of the invention.
• the impregnation depending on the position of the injection ends either before the reunification of said layers if the injection is performed at the inlet and / or between the inlet and the outlet of each channel or after the reunification if the The injection is done between the input and the output of the channels and / or the output of each channel.
• Reunification is obviously carried out by superposing said impregnated layers to obtain said impregnated fibrous material.
• said precursors impregnating said fibrous material are therefore at least partially polymerized after reunification of said layers.
• the expression “at least partially polymerized” means that the number-average molecular mass has increased by a factor of at least 2, without however exceeding 10,000, preferably 8,000.
• said fibrous material impregnated with said at least partially polymerized precursors is still located in the pultrusion head, in a single channel having its own heating system and possible jams, which allows, if necessary, to finalize the 'impregnation and / or further polymerization of the reaction mixture.
• the method as defined above is characterized in that the maximum thickness e of each layer is such that the impregnation time of each layer is less than or equal to the time required for an increase in the Mn of the reactive composition in said layer, by a factor of 5, preferably by a factor of 3, in particular by a factor of 2.
• the method as defined above is characterized in that the maximum thickness e of each n layer is subjected to the constraint of being less than or equal to a maximum limit defined as being proportional to the square root of l 'integral over the residence time t Sf of said layer in the die of the function defined as equal to the ratio of the product of the permeability K by the fluid pressure exerted on said layer P by the product of the volume fraction ci f of the composition in the fibrous medium by the viscosity of the reactive composition m, the aforementioned constant of proportionality C being less than or equal to 14, in particular less than or equal to 7, notably less than or equal to 3, namely:
• the channel is defined as representing the volume in which a layer of fibrous material travels passing through the impregnation head.
• this roving at any time of its journey is included in the volume of the channel, composed of the volume of said roving composing the layer and a free volume. Without this free volume, the material would occupy the entire volume of the canal, leading to very high friction on the walls and the premature rupture of the rovings.
• the average residence time of the reactive composition in the head is at most equal to 3, preferably 2 and even more preferably 1.5 times the residence time of said fibrous material. This makes it possible to avoid a blockage of the head because of a locally too high viscosity which blocks the movement of the layers or prevents their good impregnation.
• the channels can be of various shapes but in one embodiment, they may or may not be cylindrical, in particular cylindrical.
• a cylinder is a ruled surface whose generatrices are parallel, that is to say a surface in space made up of parallel lines.
• the ruled surface can therefore be square, rectangular, circular, elliptical (or oblong), conical, U-shaped, T-shaped ...
• the channels are cylindrical in shape, and each channel having a thickness proportional to the thickness of each n layer, the thickness of each channel is between 2 and 3 times the thickness of each n layer. , in particular between 1.5 and 2 times the thickness of each layer.
• the channels are cylindrical in shape with a rectangular surface.
• Friction points or contact areas (or contact points) can be placed
• each channel is equipped with at least one contact zone having a radius of curvature greater than d / eps rupture (d / e), d being the diameter of the fibers of the fibrous material and eps being the deformation at the breaking of the fibers, placed alternately above or below the rovings during their journey in the impregnation head to cause and / or maintain a development of the fibrous material, possibly previously initiated upstream of the head, without damaging said fibrous material.
• d / eps rupture d / eps rupture
• the deformation at break of the fibers is determined on a cylinder of carbon fiber / epoxy resin composite, by measuring the maximum elongation at break during a tensile test on this composite.
• the tensile strength of the resin in the direction of the fibers is negligible compared to the tensile strength of the fibers and therefore the elongation at break of the composite is that of the fibers.
• the radii of curvature of the contact areas on said fibrous material should not be too small so as not to damage the fibrous material.
• the radius of curvature should not be less than or equal to d / eps rupture (d / e) otherwise the fibrous material is damaged.
• each channel has up to 5 contact zones.
• each channel is devoid of contact zones placed alternately above or below the rovings as they travel through the impregnation head, in particular when the channels are conical in shape.
• thermoplastic polymer
• thermoplastic polymer is selected from: poly (aryl etherketones) (PAEK), in particular poly (etheretherketone) (PEEK) and poly (etherketonketone) (PEKK); polyaryl sulfones, in particular polyphenylene sulfones (PPSU); polyarylsulphides, in particular polyphenylene sulphides (PPS); polyamides (PA), in particular semi-aromatic polyamides (polyphthalamides) optionally modified by urea units; PEBAs, polyacrylates in particular polymethyl methacrylate (PMMA); polyolefins, in particular polypropylene, polylactic acid (PLA), polyvinyl alcohol (PVA), and fluoropolymers in particular polyvinylidene fluoride (PVDF) or polytetrafluoroethylene (PTFE) or
• PAEK poly (aryl etherketones)
• PEEK poly (etheretherketone)
• PEKK poly (etherketonketone)
• PCTFE polychlorotrifluoroethylene
• PEKK polychlorotrifluoroethylene
• PEI polychlorotrifluoroethylene
• thermoplastic polymer must be available in the form of a reactive prepolymer in order to be able to impregnate said fibrous material.
• the polyamide can be a homopolyamide or a copolyamide or a mixture thereof.
• said at least thermoplastic polymer is selected from polyamides, in particular aliphatic polyamides, cycloaliphatic polyamides and semi-aromatic polyamides (polyphthalamides), PVDF, PEEK, PEKK, PEI and a PEKK mixture and of PEI.
• polyamides in particular aliphatic polyamides, cycloaliphatic polyamides and semi-aromatic polyamides (polyphthalamides), PVDF, PEEK, PEKK, PEI and a PEKK mixture and of PEI.
• said at least thermoplastic polymer is selected from polyamides, in particular aliphatic polyamides, cycloaliphatic polyamides and semi-aromatic polyamides (polyphthalamides).
• thermoplastic polymer is a polymer whose glass transition temperature is such that Tg> 80 ° C or a semi-crystalline polymer whose melting temperature Tf>
• thermoplastic polymer is:
• an aliphatic polyamide chosen from polyamide 6 (PA-6), polyamide 11 (PA-11), polyamide 12 (PA-12), polyamide 66 (PA-66), polyamide 46 (PA-46), polyamide 610 (PA-610), polyamide 612 (PA-612), polyamide 1010 (PA-1010), polyamide 1012 (PA-1012), or a mixture thereof or a copolyamide thereof ,
• a semi-aromatic polyamide optionally modified with urea units, in particular a semi-aromatic polyamide of formula X / YAr, as described in EP1505099, in particular a semi-aromatic polyamide of formula A / XT in which A is chosen from a unit obtained from an amino acid, a unit obtained from a lactam and a unit corresponding to the formula (diamine in Ca).
• (Cb diacid) with a representing the number of carbon atoms of the diamine and b representing the number of carbon atoms of the diacid, a and b each being between 4 and 36, advantageously between 9 and 18, the unit (Ca diamine) being chosen from aliphatic, linear or branched diamines, cycloaliphatic diamines and alkylaromatic diamines and the unit (Cb diacid) being chosen from aliphatic, linear or branched diacids, cycloaliphatic diacids and aromatic diacids ;
• XT denotes a unit obtained from the polycondensation of a Cx diamine and terephthalic acid, with x representing the number of carbon atoms of the Cx diamine, x being between 6 and 36, advantageously between 9 and 18, in particular a polyamide of formula A / 6T, A / 9T, A / 10T or A / 11T, A being as defined above, in particular a polyamide PA 6 / 6T , one PA 66 / 6T, one PA 6I / 6T, one PA MPMDT / 6T, one PA MXDT / 6T, one PA PA11 / 10T, one PA 5T / 10T, one PA
• T corresponds to terephthalic acid
• MXD corresponds to m-xylylenediamine
• MPMD corresponds to methylpentamethylene diamine
• BAC corresponds to bis (aminomethyl) cyclohexane.
• thermoplastic polymer or mixture of thermoplastic polymers further comprises carbonaceous fillers, in particular carbon black or carbonaceous nanofillers, preferably chosen from carbonaceous nanofillers, in particular graphenes and / or carbon nanotubes and / or carbon nanofibrils or their mixtures.
• carbonaceous fillers in particular carbon black or carbonaceous nanofillers, preferably chosen from carbonaceous nanofillers, in particular graphenes and / or carbon nanotubes and / or carbon nanofibrils or their mixtures.
• the fibers constituting said fibrous material they are in particular continuous fibers selected from carbon, glass, silicon carbide, basalt-based, silica-based fibers, natural fibers in particular flax or hemp, lignin, bamboo, sisal, silk, or cellulosics, in particular viscose, or amorphous thermoplastic fibers with a glass transition temperature Tg greater than the Tg of said polymer or of said mixture of polymers when the latter is amorphous or greater than Tf of said polymer or of said mixture of polymers when the latter is semi-crystalline, or the semi-crystalline thermoplastic fibers with a melting point Tf greater than the Tg of said polymer or of said mixture of polymers when the latter is amorphous or greater than the Tm of said polymer or of said mixture of polymers when the latter is semi-crystalline, or a mixture of two or more of said fibers, preferably a mixture of fi bres of carbon, glass or silicon carbide, in particular carbon fibers.
• the number of fibers in said fibrous material for carbon fibers is greater than or equal to 3K, in particular greater than or equal to 6K, in particular greater than or equal to 12K.
• the number of fibers in said fibrous material for carbon fibers is greater than or equal to 12K, in particular chosen from 12K, 24K, 48K, 50K and 400K, in particular 12K, 24K, 48 K and 50K.
• the basis weight for the glass fiber is greater than or equal to 1200 Tex, in particular greater than or equal to 2400 Tex, greater than or equal to 4800 Tex.
• Tex means that 1000m of base yarn weighs 1g.
• These fibers constituting said fibrous material can be used alone or in mixtures.
• organic fibers can be mixed with mineral fibers to be impregnated with thermoplastic polymer and to form the impregnated fibrous material.
• the rovings of organic fibers can have several grammages. They can also have several geometries.
• the fibrous material consists of continuous fibers of carbon, glass, basalt or based on basalt, or of silicon carbide or a mixture thereof, in particular carbon fibers.
• the fibers of the fibrous material may or may not be sized.
• sized designates the surface treatments applied to fibrous materials during their manufacture. It can also designate a fleeting pretreatment as a preamble to the prepreg step, whether it is done directly in line with the impregnation or not.
• unsized means that the fiber is either originally unsized and that it has therefore not undergone any surface treatment, or else that the fiber has been de-sized before its use.
• thermosetting or thermoplastic resin type are generally organic in nature (thermosetting or thermoplastic resin type) and very often formulated for the pre-impregnation of reinforcing fibers of polymers with a low melting point Tf or thermosetting polymers with a low Tg point.
• unsized means that the fiber is either originally unsized and that it has therefore not undergone any surface treatment, or else that the fiber has been de-sized before its use.
• said fibrous material can comprise up to 0.1% by weight of a material of organic nature (thermosetting or thermoplastic resin type) called sizing.
• the sizing can be an organic liquid such as water, a low or high alcohol. molecular weight (ethanol, methanol, isopropanol for example), a ketone (acetone, etc.) which will play the role of fleeting sizing; that is to say that it will be present for a short time in contact with the fiber to allow its handling in the "dry" state (ie before the prepreg) and that it will then be extracted from the composite material so as not to disturb the final characteristics of the composite.
• said fibrous material can comprise from 0.1% by weight to 2.5% by weight of a material of an organic nature (thermosetting or thermoplastic resin type) called size.
• a material of an organic nature thermalsetting or thermoplastic resin type
• the fibers of the fibrous material are sized.
• the amount of fibers in said impregnated fibrous material is between 45% to 80% by volume, preferably from 50 to 65% by volume, in particular from 54 to 60%.
• the level of porosity in said impregnated fibrous material is less than 10%, in particular less than 5%, in particular less than 2%.
• the porosity level is greater than 0% but less than the rates mentioned above.
• the rate of porosity corresponds to the rate of closed porosity and can be determined either by electron microscopy or as being the relative difference between the theoretical density and the experimental density of said impregnated fibrous material as described in the examples part of the present invention.
• a step of shaping the wick or said parallel wicks of said impregnated fibrous material is carried out.
• said method defined above further comprises a step of shaping said wick or said parallel wicks of said impregnated fibrous material, by means of at least one calender or a heating shaper or cooling, in the form of a single unidirectional strip or a plurality of parallel strips, or in the form of a U or T-shaped profile or in the form of a rod or of a plurality of rods parallel unidirectional strips, said shaping device being in contact or not with said impregnation head.
• the calendering or shaping step is carried out by means of a plurality of heating or cooling calenders, or heating or cold shapers mounted in parallel and / or in series with respect to the direction of travel of the strands of fibers.
• a calendering system as described in WO 2015/121583 can be used.
• calendering by means of at least one heating calender in the form of a single unidirectional strip or sheet or of a plurality of unidirectional parallel ribbons or plies with, in the latter case, said heating calender comprising a plurality of grooves calendering, preferably up to 200 calendering grooves, in accordance with the number of said tapes and with a pressure and / or a spacing between the rolls of said calender regulated by a servo system.
• the calendering step is carried out by means of a plurality of heating calenders, mounted in parallel and / or in series with respect to the direction of travel of the strands of fibers.
• said (or said) heating calender (s) comprises (comprise) an integrated heating system by induction or by microwaves, preferably by microwaves, coupled to the presence of carbonaceous fillers in said thermoplastic polymer or mixture of polymers thermoplastics.
• a belt press is present between the pultrusion head and the calender.
• a series of post-polymerization ovens is present between the pultrusion head and the last shaper or the last calender.
• the calendering step is carried out by means of a plurality of heating calenders, mounted in parallel and / or in series with respect to the direction of travel of the strands of fibers.
• said (or said) heating calender (s) comprises (comprise) an integrated heating system by induction or by microwaves, preferably by microwaves, coupled to the presence of carbonaceous fillers in said thermoplastic polymer or mixture of polymers thermoplastics.
• said (or said) heating calender (s) is (are) coupled to a complementary heating device, located before and / or after said (each) calender, in particular a device heating by microwave or induction coupled to the presence of carbonaceous charges in said polymer or in said mixture of polymers, or an infrared heater IR, or Laser or by direct contact with another heat source.
• a complementary heating device located before and / or after said (each) calender, in particular a device heating by microwave or induction coupled to the presence of carbonaceous charges in said polymer or in said mixture of polymers, or an infrared heater IR, or Laser or by direct contact with another heat source.
• the present invention relates to a unidirectional tape of impregnated fibrous material, in particular tape wound on a spool, characterized in that it is obtained by a process comprising a shaping step as defined above.
• said tape is characterized in that the thermoplastic polymer is an aliphatic polyamide chosen PA 6, PA 11, PA 12, PA 66, PA 46, PA 610, PA 612, PA 1010, PA 1012, PA 11 / 1010 or PA 12/1010 or a semi-aromatic polyamide such as a PA MXD6 and a PA MXD10 or chosen from PA 6 / 6T, PA 6I / 6T, PA 66 / 6T, PA 11 / 10T, PA 5T / 10T, PA 11 / 5T / 10T, PA 11 / 6T / 10T, PA MXDT / 10T, PA MPMDT / 10T, PA BACT / 6T, PA BACT / 10T and PA BACT / 10T / 6T, PA BACT / 10T / 11, PA BACT / 6T / 11, one PVDF, one PEEK, PEKK and one PEI or a mixture of these.
• the thermoplastic polymer is an aliphatic polyamide
• the present invention relates to the use of the method as defined above, for the manufacture of calibrated ribbons suitable for the manufacture of three-dimensional composite parts, by automatic depositing of said ribbons by means of a robot.
• said ribbon of impregnated fibrous material is used in the manufacture of three-dimensional composite parts.
• said manufacture of said composite parts relates to the fields of transport, in particular automotive, oil and gas, in particular offshore, gas storage, aeronautics, nautical, rail; renewable energies, in particular wind turbines, tidal turbines, energy storage devices, solar panels; thermal protection panels; sports and recreation, health and medical and electronics.
• the present invention relates to a three-dimensional composite part, characterized in that it results from the use of at least one unidirectional strip of impregnated fibrous material as defined above.
• FIG. 1 describes the pultrusion head of Example 1 comprising a die, mounted at a square head, comprising a system for separating the fibers in several layers, by means of a jamming system immersed in a tank of molten resin : system suitable for the use of a non-reactive resin
• the fibrous material is separated into four but in a single impregnation chamber.
• the separated fibrous material therefore does not circulate in a channel of its own.
• FIG. 2 shows a sectional view of the morphology of the fibrous material impregnated from example 1 (pultruded profile) with the non-reactive 11 / 10T / 10T resin, using the pultrusion head described in FIG. 1.
• FIG. 3 presents the pultrusion head comprising a straight die, without dead volume and without a system for separating fibers into different layers (according to S. Lecorre, LTN, France, International Journal of Microstructure and Materials Properties ⁇ January 2012) of the example 3.
• FIG. 4 shows the morphology of the impregnated fibrous material (pultruded profile) with the pultrusion head described in FIG. 3, with a reactive composition of the 11 / 10T / 10T type.
• FIG. 5 presents the pultrusion head without dead volume and with a system for separating the fibrous material into different layers thus circulating in a channel which is specific to it of Example 4 according to the invention.
• FIG. 6 shows the morphology of a section produced with the pultrusion head described in FIG. 5 (example 4), with a reactive composition of the 11 / 6T / 10T type.
• FIG. 7 shows the morphology of a profile produced with the pultrusion head described in FIG. 5 (example 5), with a reactive composition of the BACT / 10T type.
• the polymer is an 11 / 10T / 10T with a mass of 10,000 g / mol. Its Tg is 115 ° C, its viscosity at 300 ° C is 70 Pa.s.
• the process for manufacturing the composite plate is a pultrusion process with melt impregnation with a pultrusion head comprising a die, mounted at a square head.
• the pultrusion head has a resin reservoir in which the fibers are separated into 4 layers by means of a tie-off system, as described in figure 1.
• This pultrusion head has significant dead volumes.
• the entire fiber reinforcement has a thickness of 1mm. After separation, each of the fiber layers has a thickness of about 250 ⁇ m.
• the polymer is introduced in the form of granules, compounded beforehand with a thermally stabilizing agent, into an extruder which feeds the square head.
• the temperature at which the fibers were impregnated was 300 ° C.
• the line speed was 0.5 m / min.
• the fiber used is Hypertex fiberglass of 3B SE4535
• the fiber content was 60% by volume.
• the profile obtained is a plate with a width of 200mm and a thickness of 1mm.
• the flexural stress at break remains less than 100OMPa, which is low, taking into account the fiber content (see Table 1).
• this low molar mass leads to microcracking of the pultruded profile under the effect of the residual stresses which appear during crystallization of the resin and cooling of the pultruded profile.
• the same pultrusion head as in Example 1 is used but with a reactive composition composed of two reactive prepolymers of the 11 / 6T / 10T type, with a molar mass Mn of 2500 g / mol, exhibiting a viscosity in the molten state at 300 ° C included 1 Pa.s, one being finished diCOOH, the other diNH2.
• the resin After polymerization, the resin has a Tg of 115 ° C.
• the melting of the prepolymers is done separately by means of 2 extruders.
• the prepolymers are introduced in the form of granules, into an extruder which feeds the square head.
• the temperature at which the fibers were impregnated was 300 ° C.
• the line speed was 0.8 m / min.
• the fiber used is Hypertex fiberglass of 3B SE4535
• the fiber content was 58% by volume.
• the profile obtained is a plate with a width of 200mm and a thickness of 1mm.
• the pultrusion head start-up protocol consists of using a single prepolymer to impregnate the fibers, until a stabilized speed is reached on the line.
• the second prepolymer is then introduced, which is mixed at 300 ° C. with the first prepolymer, by means of a static mixer of the Sulzer type, just before their introduction into the pultrusion head.
• the fibers are separated into 4 layers as in Example 1. All of the fibrous reinforcement has a thickness of 1 mm. After separation, each of the layers of fibers has a thickness of about 250 ⁇ m.
• the fiber impregnation is excellent but the production of the profile stops shortly after start-up because the fibers get stuck in the head. This is due to the presence of excessively large dead volumes in the pultrusion head, in which the reactive composition resides too long and therefore polymerizes, leading to a very significant viscosification of the resin and to the blocking of the fibers in about ten minutes, c 'That is to say for a time close to the polymerization time of the reactive composition and the time necessary to replace in the dead zones, the initial prepolymer by the reactive composition. This process is therefore not robust and therefore not viable.
• Example 3 Comparison Preparation of a fibrous material impregnated with 11 / 6T / 10T by reactive pultrusion without separation of layers
• the pultrusion head used is presented in figure 3, is similar to the design of the pultrusion head described in the work of Pr Steven Lecorre at LTN, in France, International Journal of Microstructure and Materials Properties ⁇ January 2012).
• This pultrusion head is distinguished by the fact that the fibers occupy a volume close to the volume of the head, ie there is no significant dead volume.
• the thickness of the final profile is 1 mm.
• the fiber content is 60% by volume.
• the thickness of the fibrous reinforcement is 1mm before impregnation and the thickness of the air gap of the pultrusion head is 2.5mm.
• the pultrusion speed is 0.8 m / min.
• the reactive composition used is composed of two reactive prepolymers of the 11 / 6T / 10T type, with a mass of 2500 g / mol and having a viscosity in the molten state at 300 ° C of 1 Pa.s, one being terminated diCOOH, the other diNH2. After polymerization, the resin has a Tg of 115 ° C.
• the melting of the prepolymers is done separately by means of 2 extruders.
• the prepolymers are introduced in the form of granules, into an extruder which feeds the square head.
• the temperature at which the fibers were impregnated was 300 ° C.
• the line speed was 0.8 m / min.
• the fiber used is Hypertex fiberglass of 3B SE4535
• the fiber content was 59% by volume.
• the profile obtained is a plate with a width of 200mm and a thickness of 1mm.
• the pultrusion head start-up protocol consists of using a single prepolymer to impregnate the fibers, until a stabilized speed is reached on the line.
• the second prepolymer is then introduced, which is mixed at 300 ° C. with the first prepolymer, by means of a static mixer of the Sulzer type, just before their introduction into the pultrusion head.
• the pultrusion speed is 1.5 m / min.
• the reactive composition used is composed of two reactive prepolymers of the 11 / 6T / 10T type, with a mass of 2500 g / mol and having a viscosity in the molten state at 300 ° C of 1 Pa.s, one being terminated diCOOH, the other diNH2. After polymerization, the resin has a Tg of 115 ° C.
• the melting of the prepolymers is done separately by means of 2 extruders.
• the prepolymers are introduced in the form of granules, into an extruder which feeds the square head.
• the temperature at which the fibers were impregnated was 300 ° C.
• the line speed was 1.5 m / min.
• the fiber used is Hypertex fiberglass of 3B SE4535
• the fiber content was 57% by volume.
• the profile obtained is a plate with a width of 200mm and a thickness of 1mm.
• the pultrusion head start-up protocol consists of using a single prepolymer to impregnate the fibers, until a stabilized speed is reached on the line.
• the second prepolymer is then introduced, which is mixed at 300 ° C. with the first prepolymer, by means of a static mixer of the Sulzer type, just before their introduction into the pultrusion head.
• 3 IR ovens of 2 m are placed in line which allow post-polymerization of the resin in the molten state, at a temperature of 300 ° C. Taking into account the line speed of 1.5m / min, the polymerization time was 4mn.
• the final shaping of the plate is carried out by means of a cold shaper, regulated at 200 ° C., placed at the outlet of the last polymerization oven.
• the absence of excessively large dead volumes in the pultrusion head allows the pultrusion process to continue for at least two hours without blocking, while the complete reaction time of the reactive composition at 300 ° C. is less than 5 minutes.
• the separation into layers of the fibrous reinforcement allows good impregnation of the fibers (see figure 6).
• the low viscosity of the prepolymers used also allows a pultrusion speed of 1.5 m / min, which is a factor in the productivity of this process.
• This reactive process is therefore compatible with reactive chemistry based on a high Tg polymer.
• the pultrusion head used is shown in Figure 5.
• This pultrusion head is distinguished by the fact that the fibers occupy a volume close to the volume of the head, that is to say that there is no dead volume. important.
• there is separation of the fibers in several layers while the thickness of the final profile is 1 min.
• the fiber content is 60% by volume.
• the total thickness of the fibrous reinforcement is 1.2mm before impregnation and in the absence of tension, the thickness of the air gap of each channel used for each of the layers is 350 ⁇ m, while each of the layers of fibers, under tension has a thickness close to 250 ⁇ m.
• the pultrusion speed is 1.5 m / min.
• the reactive composition used is composed of two reactive prepolymers of the BACT / 10T type, with a mass of 2800 g / mol and having a viscosity in the molten state at 320 ° C. of 4 Pa.s, one being terminated diCOOH, the other diNH2. After polymerization, the resin has a Tg of 140 ° C.
• the melting of the prepolymers is done separately by means of 2 extruders.
• the prepolymers are introduced in the form of granules, into an extruder which feeds the square head.
• the temperature at which the fibers were impregnated was 320 ° C.
• the line speed was 1.5 m / min.
• the fiber used is Hypertex fiberglass of 3B SE4535
• the fiber content was 58% by volume.
• the profile obtained is a plate with a width of 200mm and a thickness of 1mm.
• the pultrusion head start-up protocol consists of using a single prepolymer to impregnate the fibers, until a stabilized speed is reached on the line.
• the second prepolymer is then introduced which is mixed at 320 ° C. with the first prepolymer, by means of a static mixer of the Sulzer type, just before their introduction into the pultrusion head.
• the absence of excessively large dead volumes in the pultrusion head allows the pultrusion process to continue for at least two hours without blocking, while the complete reaction time of the reactive composition at 320 ° C. is less than 5 minutes.
• the separation into layers of the fibrous reinforcement allows good impregnation of the fibers (see figure 7).
• the low viscosity of the prepolymers used also allows a pultrusion speed of 1.5 m / min, which is a factor in the productivity of this process.
• Example 5 Determination of the porosity rate the relative difference between theoretical density and experimental density (general method)
• thermoplastic matrix The density of the thermoplastic matrix
• the number of samples must be at least 30 so that the result is representative of the material studied.
• thermogravimetric as determined for example in document B. Benzler,
• the measurement of the carbon fiber content can be determined according to ISO 14127: 2008.
• the theoretical density thus calculated is the accessible density if there is no porosity in the samples.

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