JP4119531B2 - Composite plate manufacturing method and apparatus - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a composite plate and an apparatus for carrying out said method. The invention also relates to the resulting composite product.
[0002]
[Prior art]
Starting with a woven fabric formed of both reinforcing and thermoplastic yarns as described in utility model FR2500320, the woven fabric is laminated and then the resulting laminate is hot pressed By doing so, it is already known to produce composite plates in the form of panels or curved parts. Such a method has the disadvantage of being an intermittent method.
[0003]
On the other hand, the French patent application registered in France under registration number 96/00578 is a series of woven fabrics placed on a conveyor and then preheated in a hot air oven (US Pat. No. 4,277,539). Composites based on glass / organic material fabrics, which are fed into "tape presses" (of the type of press described in the issue), where the fabrics are continuously heated and cooled and compressed overall Describes the plate manufacturing method. Such a method is high-speed, and a plate having excellent mechanical properties suitable for molding by a mold can be obtained.
[0004]
However, for some of these plates, longitudinal (conveyor direction of movement) or lateral due to poor re-weaving of the yarn after the pre-heating stage, or lateral shrinkage of the woven cloth after that stage. Misalignment of glass filaments in the direction (existence of undulations) is observed. These defects can be negligible in many applications, but they are very special applications (especially large sized flats such as cargo handling planks and supply planks that cause faulty alignment of the filament inside the product). In the production of mold thermoformed products, this may not be preferred.
[0005]
[Problems to be solved by the invention]
The present invention is an improved method and apparatus for manufacturing composite plates, which does not have the disadvantages of the existing methods and apparatuses described above, and is particularly suitable for the production of thermoformed flat products having improved characteristics. It is an object to provide a method and an apparatus capable of obtaining a plate.
[0006]
[Means for Solving the Problems]
This purpose is
The at least one yarn layer comprising at least two materials having different melting points is heated at a temperature comprised between said melting points and lower than the transformation temperature of the material having the lower melting point Continuously in the zone,
Passing the thread layer over at least one rotating bar heated at a temperature comprised between said melting points and lower than the transformation temperature of the material having the lower melting point;
Compressing the thread layer from the bar or bars and cooling the thread layer so that a composite tape is formed;
Collecting the tape in the form of one or more composite plates;
This is achieved by the method according to the invention comprising:
[0007]
According to the present invention, a “plate” is thin compared to its surface area, is usually planar (although it may be curved in some cases), and sometimes in a wound form. Usually means a rigid element with sufficient flexibility to be recovered and stored. It is usually a solid element, but may have holes in some cases (thus the term “plate” expands to also represent the lattice structure according to the invention).
The yarn layer is formed of yarns of at least two materials having different melting points. These two materials can be, for example, a thermoplastic organic material, but are preferably a thermoplastic organic material and a reinforcing material of the thermoplastic organic material (for example, glass, carbon, aramid, etc.). Usually, preferably the layer is composed of one reinforcing material (advantageously glass) and one or possibly a plurality of thermoplastic organic materials. The layer usually comprises 20 to 90% by weight of reinforcing material (preferably glass), preferably 30 to 85% by weight of reinforcing material, more particularly preferably 40 to 80% by weight of reinforcing material. The layers may include some yarns composed of one material and some yarns composed of the other material, and these yarns are arranged alternately in the layer, preferably closely mixed Is done. The layer can also include mixed yarns obtained by simultaneously combining yarns from one material and yarns from the other material, and these mixed yarns are yarns from one material and / or from the other material. It can also be mixed with yarn.
[0008]
Preferably, the yarn layer comprises at least 50% by weight (advantageously at least 80%, more particularly preferably 100%) of mixed yarns, ie yarns composed of filaments of one material and filaments of the other material. The filaments are interlaced (advantageously almost uniformly) inside the yarn, and these yarns are usually said (for example by the methods described in patent applications EP-A-0590695 and EP-A-0616055) It is obtained directly by assembling the filament during the manufacture of the filament. By using a layer with mixed yarns of at least 50% by weight, preferably at least 80%, it is possible in particular to obtain a composite material with more uniform and excellent mechanical properties, and further the production of the composite plate in a short time Also, it is advantageously carried out at a lower pressure. Preferably, these mixed yarns are composed of closely mixed glass filaments and filaments of thermoplastic organic material.
[0009]
In many cases, the yarn layer has the shape of a crossed yarn lattice or lattice assembly, preferably in the form of a woven fabric (usually a woven tape). The same yarn or yarn assembly can be used to form the warp and weft yarns of the woven or lattice, or the warp and weft yarns can be composed of different yarns or a combination of different yarns. Therefore, the yarn layer is, for example, a woven fabric in which the warp yarn is composed of a mixed yarn of organic material / reinforcing material, and the weft yarn is composed of a yarn of 80 to 100% organic material having the same property as that of the organic material of the mixed yarn. It is possible to have the shape of The resulting plate can have reinforcing yarns with a preferential orientation direction (unidirectional plate). In a particular form of unidirectional plate, the yarn layers are advantageously shaped in the form of parallel yarn bundles that are edge-to-edge or marginally spaced (the spacing between the yarns is preferably less than 2 mm). In this embodiment, these yarns are preferably mixed yarns.
[0010]
According to a preferred embodiment of the invention, the layer comprises an assembly of substantially parallel continuous yarns oriented in the direction of movement (longitudinal direction) of the layer during the method, more preferably transverse to this direction. And a second yarn assembly interlaced (preferably woven) with a substantially parallel first yarn assembly directed to.
[0011]
In the process according to the invention, the yarn layer is most often unwound from a single support, or a plurality of supports (if there are parallel yarns) on which it is wound.
[0012]
The yarn layer (moving at a speed of, for example, 0.5 to 5 m / min) is a temperature contained between the melting points of the materials constituting the layer and lower than the transformation temperature of the material having the lower melting point. The layer passes through at least one zone to be heated. In the present invention, the “transformation temperature” is defined as the minimum temperature at which decomposition of the molecules constituting the material is observed, or the ignition of the material, It represents the lowest temperature at which an undesirable change in material is observed, such as the loss of integrity (outflow of material out of the layer) or the undesirable coloration of the material (eg yellowing). This transformation temperature can be evaluated in a conventional manner by thermogravimetry and / or by recording the lowest temperature at which one of the aforementioned effects occurs.
[0013]
In the present invention, after compression, the yarn layer is capable of bonding at least a portion of the yarn to each other through a material with a lower melting point, and in most cases (except when seeking a lattice-type structure) is solid or nearly Heating is sufficient to obtain a solid structure, ie a structure with a void volume fraction of less than 5%. In case of glass / organic material composite plate, void volume ratio V _v Is the glass mass fraction (taux massique) M measured by combustion loss according to the following equation _f , Specific gravity of glass fiber ρ _f (2.6 g / cm ^Three The specific gravity of organic materials ρ _m And the specific gravity ρ of the composite material.
[0014]
V _v = 1−ρ [M _f / Ρ _f + (1-M _f ) / Ρ _m ]
For example, when the yarn layer is made of glass and polypropylene, the heating temperature can be 190 to 230 ° C., and when the layer is made of glass and poly (ethylene terephthalate) (PET) Can be 280 to 310 ° C., and the heating temperature can be 270 to 280 to 290 ° C. when the layer is composed of glass and polybutylene polyterephthalate (PBT).
[0015]
In order to ensure that the carrier structure (or a sufficiently rigid structure) is maintained inside the yarn layer during the manufacturing process, preferably the lower melting material is at least more than the melting point of the higher melting material. It has a melting point of 40 ° C., preferably at least 50 ° C. lower.
[0016]
In order to carry out the heating, it is usually preferred that at least one furnace or irradiation device, preferably at least one infrared radiation device (for example in the form of a furnace or infrared lamp or panel ...) and / or at least one hot air. A blower (for example, a forced convection hot air furnace) is used.
[0017]
In an important second stage of the method according to the invention, the yarn layer passes over a heated, at least one “rotation” (rotation around an axis transverse to the bar lengthwise) bar. This bar may optionally be in the heating zone described above, but usually at the outlet of the heating zone or following the heating zone. The layer is then already heated, preferably "partially" melted, i.e. one of these constituents is melted or possibly softened. The rotating bar can be heated at a temperature close to the temperature of the aforementioned heating zone or a temperature different from it (several or tens of degrees, for example 30 ° C. on the plus or minus side), but preferably in the heating zone Heated at a temperature higher than the temperature.
[0018]
Using this bar has several advantages. That is, with this bar, in some cases, the yarn layer can be brought at a selected angle with respect to the compression device (usually in the form of at least one two-cylinder calendar) so that when the compression device cools The layer can be prevented from coming into close contact with the device before compression, the heated rotating bar can optionally reorganize the yarn in the layer, and the lower melting point material Most of the undulations or majority that are normally found after melting can be removed without the molten material sticking or depositing on the bar. These advantages cannot be achieved at the same time when using only rotating or heated bars. Since the molten material eventually reapplies on the layer and causes poor shape inside the resulting composite tape, it must be prevented that the molten material is deposited on the bar. Moreover, it is also possible to improve the density and surface state of the tape obtained by using a bar.
[0019]
The bar is preferably cylindrical or substantially cylindrical or has a circular or substantially circular cross section, although the cross section may or may not be different. Advantageously, the diameter of the bar is small (especially compared to the calendar cylinder), and the diameter of the bar is usually small compared to its length (eg the ratio of length to diameter exceeds 15). Unlike the calendar cylinder, which is rare, the ratio of the length to the diameter of this bar is usually greater than 20). The diameter of the bar is usually from 1 to 10 cm, preferably from 2.5 to 6 cm, advantageously coated with a heat-resistant and anti-adhesive coating, the bar is for example made of polytetrafluoroethylene (PTFE) Manufactured with coated steel. Advantageously, the bar can have one or more spiral grooves or opposing spiral reliefs that assist in the stripping of the yarn layer, and in some cases may be slightly curved.
[0020]
The rotational peripheral speed of the bar is not less than the moving speed of the layer in the manufacturing equipment, particularly when the diameter of the bar is about 1 to 4 cm (for example, when the moving speed of the layer is 0.1 to 2.5 m / min, About 1 to 10 m / min, preferably 0.5 to 5 m / min), particularly when the bar has a diameter of more than 4 cm, the layer moving speed or less (for example, the moving speed of the layer is about 0.1 m / min). In the case of 5-2.5 m / min, it can be set to about 0.25-2.2 m / min). The rotation of the bar may be in the same direction as the direction of travel of the layer, or in the opposite direction, especially when the bar has a diameter of more than 4 cm.
[0021]
Usually, a single bar is necessary and sufficient to carry out the method according to the invention. However, especially when the layer has large undulations, two (or even more than two) heated rotating bars according to the invention can be used, in which case these bars are installed in sequence, so that the yarn Passes through each bar one after another (i.e., after passing one, then passing the other).
[0022]
According to the present invention, preferably the glass yarn layer has at least one heated rotating bar (or each heating if there are multiple bars) in order to obtain a significant reorganization of the filaments inside the layer. Rotated bar) and the portion of the bar (or arc relative to the central angle) defined (or opposed) by a central angle in the range of 45-200 ° (ie, the layer is in the circumference of the bar). Pass over 12.5-55.5% of the portion).
[0023]
The heated yarn layer passes through the bar or bars and is then compressed by a compression device such as at least one two-cylinder calendar. For example, when a layer passes between two cylinders of the calendar at the same time, the force applied to the layer when the layer passes through the compression device is usually several kgf / cm, and even several tens kgf / cm (this point Note that, unlike the calendar cylinder, the single (or multiple) rotating bars mentioned above cannot compress the layers and are not intended to compress the layers, The only force applied at the level is the layer tension, which usually does not exceed 0.5 kgf / cm).
[0024]
The yarn layer is compressed by the pressure applied in the compression device, and the resulting structure is cured by cooling, which can be performed at least in part at the same time as the compression, and in the hot compression stage It is also possible to do this after.
[0025]
The compression device is a calendar which is maintained at a temperature below the freezing point of this material in order to solidify at least one calendar, in particular the material with the lower melting point (this calendar is maintained at a temperature of for example 20-150 ° C. ).
[0026]
The compression device can also be equipped with a plurality of calendars, especially if it is very thick and if very good flatness and / or high production rates are desired. Also, especially when using materials with high melting points or materials with a high crystallization rate (eg polyester), and when trying to obtain solid or nearly solid plates, the outlet of the bar (or bars). By the way, it may be desirable to heat the calendar (or at least the first calendar) of the compressor at a temperature above 75 ° C., preferably 100 ° C., and even above 150 ° C. In this case, the heated calender cylinder is preferably coated with an anti-adhesion coating, for example based on PTFE, and / or a release film (silicone paper, or PTFE, for example) between each cylinder and the yarn layer. (Applied glass cloth) is fed out (in some cases this film can be in the form of a continuous tape).
[0027]
According to an embodiment of the invention, the compression device comprises a high temperature zone (especially having one or more calendars), a cooling element (in the form of bars, plates ...) and possibly one or more calendars. With a subsequent cold zone (e.g. comprising a steel, glass cloth or aramid cloth tape, preferably PTFE coated on the cloth) or comprising a tape press it can.
[0028]
In order to promote cooling of the composite tape obtained at the outlet of the aforementioned compression device, this tape passes over a cooling table with chilled water circulating inside, with a slightly higher center to improve contact with the tape. can do. In order to further improve cooling and / or contact, the table is preferably cooled (eg by water circulation) and / or free-supported or pressed singly (or plural) chilled plates and It can be coupled to one or more blast nozzles and / or the tape can be pulled by a take-off roller located at the outlet of the table, for example.
[0029]
The composite tape is wound on a reel whose diameter is determined depending on the thickness of the tape after compression and cooling (the formed plate corresponds to the wound tape) or a cutting device to form a plurality of plates It can be cut by (for example, a cutting device or a circular saw device).
[0030]
The method according to the invention has several variants. In particular, it is possible to combine a plurality of yarn layers to form a thicker plate. Thus, according to one embodiment of the present invention,
The first yarn layer comprising at least two materials having different melting points is heated at a temperature comprised between said melting points and lower than the transformation temperature of the first layer material having the lower melting point; Continuously into the heated first zone,
The second yarn layer comprising at least two materials having different melting points is heated at a temperature that is between the melting points and lower than the transformation temperature of the second layer material having the lower melting point. Continuously and simultaneously throw into the zone where the layer is heated (usually the second zone)
The first layer is heated at a temperature comprised between the melting points of the material of the first layer and lower than the transformation temperature of the material having the lower melting point; Pass over the rotating bar
The second layer is heated at a temperature comprised between the melting points of the materials of the second layer and at a temperature lower than the transformation temperature of the material having the lower melting point; Pass through the rotating bar at the same time,
Combine the two layers and compress it at the same time as it emerges from at least one of the bars or series of bars and cool the whole so that a composite tape is formed,
• Collect tape in the form of one or more composite plates.
[0031]
According to this embodiment, a thicker plate can be obtained. Similarly, multiple yarn layers can be combined depending on the desired plate thickness, with each layer passing over a heating zone and then one or a series of bars, all layers being one bar or multiple Combining in one or more stages at the end of the bar or series of bars and then compressing the assembly. In particular, it is possible to bond the first layers, for example two at a time as they emerge from the bar, and the final combination of the layer assembly is that the last layer or the last pair or layer of the assembly has one or more bars. Because it is done where it passes through, the combined layer or layers are optionally finally combined after being compressed and / or reheated. Such a configuration is shown later in particular in FIG.
[0032]
Also, before compressing the assembly, one or more surface films can be unwound onto one or two sides of the layer or tie layer, and these films are hot bonded to the layers. These films may be the same as or different from the material of the yarn layer (or one of the materials) (the film can be metal, organic, etc.), but a single (multiple) layer It is preferable to have a coating with properties close to those of the material with a lower melting point inside.
[0033]
More generally, one or more plates, or lattices, or other planar structures (eg yarns, lattices, woven fabrics, honeycomb structures, or powders, mainly of metallic, polymeric, inorganic or wooden nature) Or a structure containing elements in the form of liquids, foils, panels, or films), continuous or discontinuous, unlike layers, and characteristic properties (additional reinforcement with yarns of different properties) unique to the resulting composite plate , Improving mechanical properties, protection against electromagnetic radiation, improving thermal insulation or sound insulation, light weight composite structure, improving moldability, surface appearance ... And / or can be inserted between multiple layers.
[0034]
The invention also relates to an apparatus for carrying out the method. This device
a) one or more devices (or mechanisms) for supplying at least one yarn layer;
b) at least one layer heating device (or mechanism);
c) at least one heated rotating bar on the passage of the layer;
d) at least one device (or mechanism) for compressing and optionally cooling the layer;
including.
[0035]
According to the invention, the aforementioned mechanisms a, b, c and d are advantageously different mechanisms, so that the device according to the invention comprises at least four different mechanisms, each performing a separate function.
[0036]
The device according to the invention can also comprise at least one cutting device and / or a recovery device for the composite plate. The device according to the invention can also comprise at least one layer cooling device different from the compression device d.
[0037]
The composite plate obtained by combining the steps of the method according to the invention is embedded in the plate and is generally at least partly arranged in the direction of movement of the plate during the manufacture of the plate, preferably the other part (or alternatively At least the other part of the filament includes a filament (usually a reinforcing filament) of a higher melting point material that is also disposed in a direction transverse to the direction of movement. Thus, the plate is disposed substantially parallel to at least one assembly of higher melting filament material disposed substantially parallel according to the first direction and, optionally, preferably according to a second direction transverse to the first direction. And at least one second assembly of higher melting point filament material, all of which are embedded in the lower melting point material and each filament has relief (or displacement) relative to the direction of the filament material. The size is less than 0.5 mm (in the conventional composite plate manufacturing method, the size of the undulation may reach 2 to 6 mm). Furthermore, the solid plate obtained by the present invention has a void volume ratio of less than 5%.
[0038]
Other advantages and features of the invention will become apparent from the following drawings, which illustrate the invention in a non-limiting manner.
[0039]
DETAILED DESCRIPTION OF THE INVENTION
In the embodiment shown in FIG. 1, a supply device (feeding device) A ₁ Is supplied with a woven fabric 1 of glass / polypropylene mixed yarn. This woven fabric passes through a bypass roller 2 having a diameter of 10 to 20 cm, and then enters an infrared radiation furnace 3 where the polypropylene filaments in the woven fabric are melted. The woven fabric is then coated with PTFE with a diameter of 1-5 cm, heated at a temperature above the melting point of polypropylene, and rotated in a direction opposite to the direction of movement of the woven fabric at an adjustable rotational speed. 4 is partially molten.
[0040]
In this way, the woven fabric with the glass filaments in a row, which was removed by both the bar and the tension (especially the payout) acting on the woven fabric, was then maintained at a temperature below the freezing point of the polypropylene, It enters a two-cylinder calendar 5 having a diameter of 20 to 80 cm each, comes out in the form of a composite tape B, and is cooled by a cooling table 6. In order to improve the contact between the tape and the cooling table, the tape is drawn by the take-in roller 7 and pressed against the table by the cooled compression roller 8.
[0041]
Next, the tape is wound on a reel (not shown) or cut into a plate shape by a device such as a circular saw device installed on a follower.
[0042]
In this embodiment of the invention, the second supply device A ₂ It is also possible to supply another glass / polypropylene mixed woven fabric 9 from the two, the two supply devices being arranged vertically on both sides of the production line (after heating by supplying the woven fabric vertically) Can prevent warping of the woven fabric). After passing through the bypass roller 10, the second woven fabric enters another infrared radiation furnace 11 and is then coated with PTFE and another steel heated at about the same temperature as the first bar described above. Move to the bar 12 made of metal. Next, the woven fabrics 1 and 9 are simultaneously compressed by the calendar 5 to form a thicker tape than when only one woven fabric is used.
[0043]
In this embodiment, one or two surface films 13 and / or 14 can also be bonded to one or both sides of the tape by melting.
[0044]
It is also possible to obtain a thicker plate by inserting a plate 15 (for example, of the same nature) fed from the feeding device 16 with tension controlled between the two woven fabrics 1 and 9. The surface of the plate 15 is preheated by a furnace 17 to maximize compression of the plate / woven assembly within the calendar 5.
[0045]
In the embodiment shown in FIG. 2, the above-described plate inserted between two woven fabrics is replaced with another two woven fabrics, namely the feeding device A. _Three , A _Four From the bypass rollers 20, 21, then the infrared radiation furnaces 22, 23, then the same bars 24, 25 as the above two bars, and then simultaneously compressed by the calender 5, The first tape B ′ of the woven fabric obtained by assembling the two woven fabrics 18 and 19 forming the first tape is replaced. This embodiment uses two melting / calendar modules.
[0046]
In the embodiment shown in FIG. 3, the following changes are made to the embodiment shown in FIG. That is, the four woven fabrics 1, 9, 18, and 19 are directly assembled at the level of the calendar 5 to which they are simultaneously compressed, and each woven fabric is supplied from a feeding device and preheated in an infrared radiation furnace. Each woven fabric is placed on two similar heated rotating bars (4, 12, 24, 25, 26, 27, 28, 29) to increase the effect before being compressed in the calendar. Each of these moves further, and these bars cause the woven fabric to have a selected angle at the level of the calendar 5 so that all the woven fabrics can be joined directly at the level of the calendar.
[0047]
In the embodiment shown in FIG. 4, an apparatus similar to the apparatus shown in FIG. 1 is used to produce plates from a woven fabric of glass / polyethylene terephthalate (PET) blended yarn. In this embodiment, the calendar 30 is now heated and the calendar cylinder is covered with PTFE.
[0048]
If the polymer is still deposited on the cylinder of the calendar 30, it may be advantageous to simultaneously feed out two release films 31 and 32 of silicone paper or glass cloth coated with PTFE, for example. These films are respectively fed from the feeding devices 33 and 34 and wound on the rotating supports 35 and 36, respectively. This configuration does not prohibit the adhesion of the surface films 13 and 14. Two continuous tapes 37 and 38 of the same nature (or aramid / PTFE or metal) may be preferred over two glass / PTFE release films.
[0049]
If it is very thick and requires very good flatness, it may be advantageous to replace the cooling table 6 with a plurality of double roller calenders. Therefore, in the embodiment shown in FIG. 5, the cooling table of the apparatus of FIG. 3 is replaced with two calendars 39 and 40.
[0050]
If it is necessary to heat the first calendar 5, it is possible to install two release tapes 41 and 42 that pass between the two additional calendars.
[0051]
It is also possible to replace the calendar or calendars and possibly the cooling table with a tape press as shown in FIG. 6 (for example, the device upstream of the rotating bar, not shown). Is possible. This press has a high temperature zone (cylinder 43, plates 44 and 45, and optionally calendar 46), a low temperature zone (optional calendar 46 and plates 47 and 48), and glass (or aramid) coated with, for example, PTFE. And cloth tapes 49 and 50.
[0052]
The following examples show in a non-limiting manner the method according to the invention as well as the products obtained by this method.
[0053]
Example 1
In order to produce a plate with a width of 1.3 m and a thickness of 1 mm composed of 60% by weight of glass and 40% by weight of black polypropylene in the mass, the equipment described with reference to FIG. Use a single calendar facility such as
[0054]
710 g / m formed of 790 tex mixed roving yarn with 60% glass by weight and 40% polypropylene by weight ² The two woven fabrics are each heated in individual furnaces of similar power of about 14 kW. The temperature at the surface of the woven fabric is about 190 ° C. The bar with a diameter of 32 mm is heated at 230 ° C. and rotates in a direction opposite to the moving direction of the woven fabric at a speed of 7 revolutions / minute (0.7 m / min).
[0055]
A 40 ° C. calendar comprising two cylinders each having a diameter of 300 mm presses the woven fabric with a force of 2600 daN / m.
[0056]
The plate comes out continuously at a speed of 1.3 m / min. The plate can be wound on a reel having a diameter of at least 160 mm.
[0057]
The resulting plate has a void volume fraction of less than 5%, so this plate is suitable for thermoforming in low temperature or heated molds (eg 80 ° C.) with a cycle of less than 1 minute.
[0058]
Example 2
In order to produce a plate having a width of 1.3 m and a thickness of 2 mm composed of 60% by weight of glass and 40% by weight of black polypropylene in the mass, the plate obtained in Example 1 (plate 15 in FIG. 1) was used. The equipment of Example 1 having a third feeding device for feeding is used.
[0059]
710 g / m similar to the woven fabric used in Example 1 ² The two fabrics are heated in a furnace similar to the furnace used in Example 1. The temperature at the surface of the woven fabric is about 210 ° C. The bar with a diameter of 32 mm is heated at 230 ° C. and rotates in a direction opposite to the moving direction of the woven fabric at a speed of 7 revolutions / minute.
[0060]
The core plate is heated at 130 ° C. in a furnace adjusted to about 10 kW.
[0061]
Two surface films made of black polypropylene having a thickness of 50 μm (films 13 and 14 in FIG. 1) are hot-bonded to the surface of the tape obtained by combining a woven fabric and a core plate.
[0062]
A 65 ° C. calendar with two cylinders each having a diameter of 300 mm presses the tape with a force of 2600 daN / m.
[0063]
The tape formed of four woven fabrics and two black films comes out continuously at a speed of 1.2 m / min. The tape is cut in the transverse direction to make a 2 m long plate.
[0064]
The void volume ratio of each obtained plate is less than 5%.
[0065]
Example 3
To produce a 1.5m wide, 1mm thick plate composed of 75% by weight glass and 25% by weight unprocessed polypropylene, a 0.4mm plate with 75% glass and 25% polypropylene. The equipment of Example 1 having a third feeding device for feeding out is used.
[0066]
560 g / m formed from 690 tex interlaced roving yarn with 75% glass by weight and 25% by weight polypropylene. ² The two fabrics are heated in a furnace similar to the furnace used in Example 1. The temperature at the surface of the woven fabric is about 220 ° C. A bar with a diameter of about 30 mm is heated at 230 ° C. and rotates in a direction opposite to the moving direction of the woven fabric at a speed of 7 revolutions / minute.
[0067]
The core plate is heated at 130 ° C. in a furnace adjusted to about 10 kW.
[0068]
A 34 ° C. calendar with two cylinders each 300 mm in diameter presses the assembly with a force of 3600 daN / m.
[0069]
The tape formed by the three elements comes out continuously at a speed of 1.2 m / min. The tape is cut into 1.5 m long plates.
[0070]
Example 4
The equipment of Example 3 is used to produce a 1.4 m wide, 1 mm thick plate composed of 65 wt% glass and 35 wt% unprocessed PET.
[0071]
660 g / m composed of 730-tex mixed roving yarn with 65% glass and 35% PET ² The two woven fabrics are heated at a temperature of about 290 ° C. A bar with a diameter of 32 mm is heated at 290 ° C. and rotates in a direction opposite to the moving direction of the woven fabric at a speed of 7 revolutions / minute.
[0072]
A core plate of 65% glass and 35% PET is heated at 220 ° C. in a furnace adjusted to about 14 kW.
[0073]
A 200 ° C. calendar with two cylinders 300 mm in diameter and covered with PTFE presses the assembly with a force of about 3850 daN / m.
[0074]
The tape formed of three woven fabrics comes out continuously at a speed of 1 m / min. The tape is cut into 2.5 m long plates.
[0075]
Example 5
The equipment of Example 3 is used to produce a 1.4 m wide, 1 mm thick plate composed of 65 wt% glass and 35 wt% unprocessed PBT.
[0076]
660g / m composed of 730 tex mixed roving yarn with 65% glass and 35% PBT ² Are heated at a temperature of about 280 ° C. A bar with a diameter of 50 mm is heated at 290 ° C. and rotates in the moving direction of the woven fabric at a speed of 0.9 m / min.
[0077]
A core plate of 65% glass and 35% PBT is heated at about 210 ° C. in a furnace adjusted to about 12 kW.
[0078]
A calender with two steel cylinders with a diameter of 300 mm at 120-140 ° C. presses the assembly with a force of about 3850 daN / m.
[0079]
The tape formed of three woven fabrics comes out continuously at a speed of 1 m / min. The tape is wound on a reel having a diameter of 300 mm.
[0080]
The plates formed by the method of the invention are very suitable for the production of thermoformed products, in particular large flat products, or machine protective covers or casings.
[Brief description of the drawings]
FIG. 1 is a schematic diagram of an apparatus capable of performing the first method of implementation of the present invention.
FIG. 2 is a schematic diagram of an apparatus capable of performing the second method of implementation of the present invention.
FIG. 3 is a schematic diagram of an apparatus capable of performing the third method of implementation of the present invention.
FIG. 4 is a schematic diagram of an apparatus capable of performing the fourth embodiment of the present invention.
FIG. 5 is a schematic diagram of an apparatus capable of performing the fifth embodiment of the present invention.
FIG. 6 is a schematic diagram of a portion of an apparatus implementing the present invention.
[Explanation of symbols]
1, 9, 18, 19 Woven fabric
2, 10, 20, 21 Bypass roller
3, 11, 22, 23 Infrared radiation furnace
4, 12, 24, 25, 26, 27, 28, 29 bar
5, 30, 39, 40, 46 Calendar
6 Cooling table
7 Roller
8 Compression roller
13, 14 Surface film
15 plates
16, 33, 34 Feeding device
17 Furnace
18, 19 Woven fabric
31, 32 Release film
35, 36 Support
37, 38 continuous tape
41, 42 Release tape
43 cylinders
44, 45, 47, 48 plates
49, 50 tapes
A ₁ , A ₂ , A _Three , A _Four Supply device

Claims (7)

A zone in which at least one yarn layer comprising at least two materials having different melting points is heated at a temperature comprised between said melting points and lower than the transformation temperature of the material having the lower melting point Continuously into
Passing the thread layer over at least one rotating bar heated at a temperature comprised between said melting points and lower than the transformation temperature of the material having the lower melting point;
Compress the thread layer coming out of the bar or bars, cool the thread layer so that a composite tape is formed,
A method of manufacturing a composite plate that collects tape in the form of one or more composite plates.   The method of claim 1, wherein the yarn layer comprises at least 50% by weight of mixed yarn.   3. A method according to claim 2, characterized in that the intermingled yarn is mainly composed of closely interlaced glass filaments and filaments of thermoplastic organic material.   4. A method according to claim 1, wherein the yarn layer is in the form of a woven fabric. At least one further yarn layer comprising at least two materials having different melting points at a temperature comprised between said melting points and lower than the transformation temperature of the material of another yarn layer having a lower melting point. Continuously put into a zone where another yarn layer is heated,
On at least one second rotating bar heated at a temperature comprised between the melting points of the materials of the other yarn layers and below the transformation temperature of these materials having a lower melting point Pass through
Combine the two layers, compress it at the same time out of at least one of their bars, cool the whole so that a composite tape is formed,
The method according to any one of claims 1 to 4, characterized in that the tape in the form of one or more composite plates is collected.   Combining and simultaneously compressing a plurality of woven fabrics and / or bonded fabrics and / or yarn layers and / or lattices and / or honeycomb structures and / or plates and / or films at least from one rotating bar A method according to any one of claims 1 to 5, characterized in that: An apparatus for producing at least one composite plate,
a) one or more mechanisms for supplying at least one yarn layer;
b) at least one yarn layer heating mechanism;
c) at least one heated rotating bar on the passage of the yarn layer;
d) an apparatus comprising at least one mechanism for compressing and optionally cooling the yarn layer.

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