ES2561052T3 - Procedimiento para la fabricación de telas de fibra de carbono y telas fabricadas con este procedimiento - Google Patents

Procedimiento para la fabricación de telas de fibra de carbono y telas fabricadas con este procedimiento Download PDF

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ES2561052T3
ES2561052T3 ES13713525.7T ES13713525T ES2561052T3 ES 2561052 T3 ES2561052 T3 ES 2561052T3 ES 13713525 T ES13713525 T ES 13713525T ES 2561052 T3 ES2561052 T3 ES 2561052T3
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fabric
polyurethane
protective layer
silicone
carbon fiber
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Attilio Masini
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Automobili Lamborghini SpA
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Automobili Lamborghini SpA
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/18—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials
    • D06N3/183—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials the layers are one next to the other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
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    • B32—LAYERED PRODUCTS
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
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    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B32B37/156—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is calendered and immediately laminated
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D06M15/263—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acids; Salts or esters thereof
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D06M15/564—Polyureas, polyurethanes or other polymers having ureide or urethane links; Precondensation products forming them
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/643—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds containing silicon in the main chain
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M17/00—Producing multi-layer textile fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M17/00—Producing multi-layer textile fabrics
    • D06M17/04—Producing multi-layer textile fabrics by applying synthetic resins as adhesives
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M17/00—Producing multi-layer textile fabrics
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    • D06M17/08—Polyamides polyimides
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M17/00—Producing multi-layer textile fabrics
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Laminated Bodies (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Woven Fabrics (AREA)
  • Inorganic Fibers (AREA)

Abstract

Procedimiento para la fabricación de telas de fibra de carbono, en el que una tela de fibra de carbono (1) se impregna con una emulsión de silicona, poliuretano o acrílica (4) que, a continuación, se seca conjuntamente con la tela (1), caracterizado porque, como mínimo, una capa protectora (2) que comprende una película, una tela tejida o una tela no tejida se aplica sobre una cara de la tela (1).

Description

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DESCRIPCION
Procedimiento para la fabricacion de telas de fibra de carbono y telas fabricadas con este procedimiento.
La presente invencion se refiere a un procedimiento para la fabricacion de telas de fibra de carbono, en particular, una tela flexible que se puede utilizar para recubrir partes internas de vehlculos a motor. La presente invencion tambien se refiere a un recubrimiento para vehlculos a motor que comprenden esta tela.
Las telas de fibras de carbono conocidas comprenden una malla de filamentos finos de fibras de carbono dispuestos de forma perpendicular entre si. Estas telas conocidas se impregnan con resinas polimericas y se solapan de acuerdo con direcciones adecuadas. Las resinas se curan para obtener materiales rlgidos con una resistencia especlfica elevada, que son adecuados para la produccion de partes estructurales o partes decorativas. Estos materiales, debido a su caracterlstica de rigidez, no pueden aplicarse, por ejemplo, a partes internas de vehlculos a motor, en las que se requieren telas flexibles que puedan coserse y doblarse. Esto tambien excluye la utilizacion de telas en bruto hechas de fibra de carbono, las cuales tienden a deshebrarse y no son capaces de mantener inalterada la disposicion de las fibras una vez se deforman.
Los documentos JP-A-2007169867, JP-A-2003278083, JP-A-2011162897, EP 415254 A2 y JP-A-2004149980 dan a conocer procedimientos o productos en los que una tela de fibra de carbono se impregna con una emulsion de silicona o uretano.
El objetivo de la presente invencion, por lo tanto, es dar a conocer una tela hecha de fibra de carbono, que no presente las desventajas mencionadas. Dicho objetivo se consigue con un procedimiento, una tela y un recubrimiento, cuyas caracterlsticas principales se especifican en las reivindicaciones 1, 18 y 20, mientras que en las reivindicaciones restantes se especifican otras caracterlsticas.
Gracias a sus caracterlsticas particulares, la tela segun la presente invencion puede utilizarse de forma ventajosa para productos y accesorios de prendas de ropa o de piel, en particular, bolsos, as! como para otras aplicaciones que requieran una tela flexible, tales como, por ejemplo, recubrimientos de asientos y paredes interiores, en particular, de vehlculos a motor. De hecho, la tela segun la presente invencion no se deshilacha incluso cuando las costuras tensionan las fibras. Ademas, incluso si se deforma a lo largo de dos ejes transversales de curvatura, concretamente con deformaciones concavas o convexas, la tela mantiene una disposicion sustancialmente perpendicular y un deslizamiento longitudinal limitado de las fibras, con el fin de evitar las deformaciones permanentes de su estructura.
Se aplica una capa protectora especlfica a la tela para mejorar la manipulacion durante la fabricacion y/o para limitar la flexibilidad de la tela, as! como para hacerla resistente, impermeable, aislante, semitransparente, no transparente y/u opaca.
La tela segun la presente invencion es agradable al tacto y tiene una resistencia elevada, superior a la de una tela en bruto de fibra de carbono, a la vez que mantiene una flexibilidad extrema que tambien permite crear pliegues o dobladillos en la misma tela sin que se comprometa su integridad. La tela tambien es muy elastica, dado que su impregnacion especlfica asegura una disposicion correcta de la textura, incluso despues de las deformaciones. Por lo tanto, es posible deformar esta tela sin que se comprometa su textura y sin provocar que se deshebren las fibras.
Segun un aspecto de la presente invencion, la emulsion especlfica de silicona, poliuretano o acrllica tambien impregna las fibras mas interiores de la tela de fibra de carbono, con el fin de que se obtenga una tela resistente al desgaste superficial, pero permaneciendo extremadamente flexible.
Como mlnimo, un borde de la tela en su configuration final esta preferentemente doblado y cosido sobre si mismo, con el fin de que forme un dobladillo que evite el deshebrado de las fibras de las capas mas interiores de la tela.
Otras ventajas y caracterlsticas de la tela y del procedimiento segun la presente invencion seran evidentes para los expertos en la tecnica a partir de la siguiente description detallada y no limitante de una realization de la misma con referencia a los dibujos que se acompanan en los que:
- La figura 1 muestra una section parcial de la tela durante una etapa del procedimiento;
- La figura 2 muestra la tela de la figura 1 durante una etapa posterior del procedimiento;
- La figura 3 muestra la tela de la figura 1 durante una etapa posterior del procedimiento; y
- La figura 4 muestra la tela de la figura 1 durante otra etapa del procedimiento.
Haciendo referencia a la figura 1, se observa que la tela -1- segun la presente invencion comprende, como mlnimo, un tejido, en particular, pano, tela cruzada o saten, de hilos de fibra de carbono que tiene una densidad lineal entre 50 y 5.000 g/km y comprende de 1.000 a 60.000 filamentos, en particular, de 3.000 a 24.000 filamentos que tienen un diametro comprendido entre 5 y 10 micras. El espesor de la tela -1- esta comprendido entre 50 y 1.000 micras. El peso de base de la tela -1- esta comprendido entre 170 y 270 g/m2, en particular, entre 210 y 220 g/m2.
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En una primera etapa de trabajo preliminar, para asegurar la regularidad y el buen acabado estetico del tejido, la tela -1- se cepilla y/o estira a una temperatura comprendida entre 30oC y 200oC y/o a una presion comprendida entre 1 y 100 bar mediante dos cilindros o dos placas adecuadas para ejercer una presion variable.
En una segunda etapa de trabajo preliminar, se aplica, como mlnimo, una capa protectora -2-, que comprende, en particular, una pellcula, una tela tejida o una tela no tejida, mas en particular, una pellcula de poliuretano, poliamida o acrllica, sobre una cara de la tela -1-. El espesor de la capa protectora -2- esta comprendido entre 50 y 500 micras. El peso de base de la capa protectora -2- esta comprendido entre 20 y 40 g/m2, en particular entre 25 y 35 g/m2. La capa protectora -2- se aplica a la tela -1- mediante laminacion, en particular, calandrado o prensado en caliente, en los que la tela -1- y la capa protectora -2- se laminan conjuntamente a una temperatura comprendida entre 30oC y 200oC y/o a una presion entre 10 y 200 bar. Durante esta etapa de trabajo la superficie de la capa protectora -2- en contacto con la tela -1- penetra parcialmente en la tela -1-, con el fin de crear una capa intermedia -3-, que tiene un espesor comprendido entre el 5% y el 60% del espesor de la tela -1-, en la que los filamentos exteriores de la tela -1- se integran en la capa protectora -2-.
Haciendo referencia a la figura 2, se observa que en una etapa de trabajo principal la tela -1- se impregna con una emulsion de silicona, poliuretano o acrllica -4- por medio de pulverizadores -5-, o mediante embadurnado, inmersion o con un procedimiento de transferencia en fusion (“hot-melt”). Los pulverizadores -5- se disponen sobre la cara opuesta de la tela -1- con respecto a la capa protectora -2-, concretamente la tela -1- esta comprendida entre la capa protectora -2- y los pulverizadores -5-. La tela -1- con la emulsion de silicona, poliuretano o acrllica -4- se presiona por rodillos de laminacion a una presion ejercida por los rodillos comprendida entre 1 y 100 bar para hacer penetrar la emulsion de silicona, poliuretano o acrllica -4- en la tela -1- y eliminar la cantidad en exceso.
En una etapa posterior del procedimiento la emulsion de silicona, poliuretano o acrllica -4- en la tela -1- se seca, en particular, mediante un tratamiento termico en un horno a una temperatura comprendida entre 20oC y 200oC, durante un tiempo comprendido entre 2 y 40 horas. Al final de esta etapa de secado la tela -1- se impregna con un porcentaje de emulsion de silicona, poliuretano o acrllica -4- comprendido entre el 1% y el 60% del peso de la tela -1-.
Con referencia a la figura 3, se observa que en una etapa posterior opcional del procedimiento, se pulveriza una solucion alifatica -6- mediante los mismos pulverizadores -5- u otros pulverizadores sobre la tela -1-, con el fin de aplicar un peso de base de la solucion alifatica -6- comprendido entre 48 y 90 g/m2, en particular, 55 g/m2 ± 10% u 80 g/m2 ± 10%, despues de lo cual la solucion alifatica -6- se seca.
La solucion alifatica -6- comprende poliacrilatos, glicoles y/o compuestos de poliuretano alifatico, en particular opacificantes. La solucion alifatica -6- tambien puede comprender cadenas de silicio-oxlgeno.
Con referencia a la figura 4, se observa que en una etapa adicional opcional del procedimiento, se pulveriza una emulsion acuosa -7- de isocianato y/o sustancias de poliurea reticulantes por medio de los mismos pulverizadores -5- o de otros pulverizadores sobre la tela -1-, despues de lo cual esta emulsion acuosa -7- se seca.
El peso de base de la tela -1- al final del proceso esta comprendido preferentemente entre 260 y 320 g/m .
En una realizacion alternativa, la emulsion de silicona, poliuretano o acrllica -4- puede aplicarse a la tela -1- de la manera descrita anteriormente antes de la aplicacion de la capa protectora -2-.
En una etapa de trabajo final, como mlnimo, un borde de la tela -1- impregnado con la emulsion de silicona, poliuretano o acrllica -4- y unido a la capa protectora -2-, si existe, se dobla y cose sobre si mismo con el fin de formar un dobladillo.
Los expertos en la tecnica pueden realizar posibles variantes y/o adiciones a la realizacion de la presente invencion descrita e ilustrada en el presente documento manteniendose dentro del alcance de las siguientes reivindicaciones. En particular, realizaciones adicionales de la presente invention pueden incluir las caracterlsticas tecnicas de una de las siguientes reivindicaciones, con la adicion de una o mas caracterlsticas tecnicas, tomadas individualmente o en cualquier combination mutua, descritas en el texto y/o ilustradas en los dibujos.

Claims (20)

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    REIVINDICACIONES
    1. Procedimiento para la fabricacion de telas de fibra de carbono, en el que una tela de fibra de carbono (1) se impregna con una emulsion de silicona, poliuretano o acrllica (4) que, a continuacion, se seca conjuntamente con la tela (1), caracterizado porque, como mlnimo, una capa protectora (2) que comprende una pellcula, una tela tejida o una tela no tejida se aplica sobre una cara de la tela (1).
  2. 2. Procedimiento, segun la reivindicacion anterior, caracterizado porque la emulsion de silicona, poliuretano o acrllica (4) se aplica a la tela (1) mediante pulverizacion (5), embadurnado, inmersion o por un procedimiento de transferencia en fusion (“hot-melt”).
  3. 3. Procedimiento, segun una de las reivindicaciones anteriores, caracterizado porque la tela (1) se impregna con un porcentaje de emulsion de silicona, poliuretano o acrllica (4) comprendido entre el 1% y el 60% del peso de la tela (1).
  4. 4. Procedimiento, segun una de las reivindicaciones anteriores, caracterizado porque antes del secado de la tela (1) con la emulsion de silicona, poliuretano o acrllica (4) se presiona a una presion comprendida entre 1 y 100 bar.
  5. 5. Procedimiento, segun una de las reivindicaciones anteriores, caracterizado porque la capa protectora (2) se aplica mediante laminacion a la cara de la tela (1).
  6. 6. Procedimiento, segun una de las reivindicaciones anteriores, caracterizado porque la emulsion de silicona, poliuretano o acrllica (4) se aplica a la tela (1) antes de que la capa protectora (2) se aplique a la tela (1).
  7. 7. Procedimiento, segun una de las reivindicaciones anteriores, caracterizado porque la capa protectora (2) comprende una pellcula de poliuretano, poliamida o acrllica.
  8. 8. Procedimiento, segun una de las reivindicaciones anteriores, caracterizado porque la capa protectora (2) se aplica a la tela (1) mediante una laminacion, en particular, un calandrado o prensado en caliente, en el que la superficie de la capa protectora (2) que esta en contacto con la tela (1) penetra parcialmente en la tela (1), con el fin de crear una capa intermedia (3) en la que los filamentos exteriores de la tela (1) estan integrados en la capa protectora (2).
  9. 9. Procedimiento, segun la reivindicacion anterior, caracterizado porque el espesor de la capa intermedia (3) esta comprendido entre el 5% y el 60% del espesor de la tela (1).
  10. 10. Procedimiento, segun una de las reivindicaciones 5 a 9, caracterizado porque dicha laminacion se lleva a cabo a una temperatura comprendida entre 30oC y 200oC y/o a una presion comprendida entre 10 y 200 bar.
  11. 11. Procedimiento, segun una de las reivindicaciones anteriores, caracterizado porque una solucion alifatica (6) se pulveriza sobre la tela (1), despues de lo cual esta se seca.
  12. 12. Procedimiento, segun la reivindicacion anterior, caracterizado porque el peso de base de la solucion alifatica (6) esta comprendido entre 48 y 90 g/m2, en particular, 55 g/m2 ± 10% u 80 g/m2 ± 10%.
  13. 13. Procedimiento, segun la reivindicacion 11 o 12, caracterizado porque la solucion alifatica (6) comprende poliacrilatos, glicoles y/o compuestos de poliuretano alifatico, en particular opacificantes.
  14. 14. Procedimiento, segun una de las reivindicaciones 11 a 13, caracterizado porque la solucion alifatica (6) comprende cadenas de silicio-oxlgeno.
  15. 15. Procedimiento, segun una de las reivindicaciones anteriores, caracterizado porque se pulveriza una emulsion acuosa (7) de isocianato y/o sustancias de poliurea reticulantes sobre la tela (1), despues de lo cual esta se seca.
  16. 16. Procedimiento, segun una de las reivindicaciones anteriores caracterizado porque el peso de base de la tela (1) al final del procedimiento esta comprendido entre 260 y 320 g/m2.
  17. 17. Procedimiento, segun una de las reivindicaciones anteriores, caracterizado porque, como mlnimo, un borde de la tela (1) impregnado con la emulsion de silicona, poliuretano o acrllica (4) y unido a la capa protectora (2), se dobla y cose sobre si mismo con el fin de formar un dobladillo.
  18. 18. Tela de fibra de carbono (1), caracterizada porque se fabrica con el procedimiento segun una de las reivindicaciones anteriores.
  19. 19. Tela, segun la reivindicacion anterior, caracterizada porque es deformable a lo largo de dos ejes de curvatura transversales.
  20. 20. Revestimiento para vehlcuios a motor, caracterizado porque comprende una tela, segun la reivindicacion 18 o 19.
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