NO174770B - Fremgangsmåte for fremstilling av laminerte forsterkede termoplastiske ark - Google Patents

Fremgangsmåte for fremstilling av laminerte forsterkede termoplastiske ark Download PDF

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Publication number
NO174770B
NO174770B NO873138A NO873138A NO174770B NO 174770 B NO174770 B NO 174770B NO 873138 A NO873138 A NO 873138A NO 873138 A NO873138 A NO 873138A NO 174770 B NO174770 B NO 174770B
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Norway
Prior art keywords
sheets
laminate
thermoplastic
consolidated
fibers
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NO873138A
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English (en)
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NO873138D0 (no
NO873138L (no
NO174770C (no
Inventor
Ian Stedman Biggs
Bronislaw Radvan
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Wiggins Teape Group Ltd
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Publication of NO873138D0 publication Critical patent/NO873138D0/no
Publication of NO873138L publication Critical patent/NO873138L/no
Publication of NO174770B publication Critical patent/NO174770B/no
Publication of NO174770C publication Critical patent/NO174770C/no

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    • 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
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • 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
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • 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
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • 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
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • 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
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • 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
    • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • B32B27/285—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyethers
    • 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
    • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • B32B27/288—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyketones
    • 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
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • 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
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • 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
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B32B27/365—Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0036—Heat treatment
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/16—Drying; Softening; Cleaning
    • B32B38/164—Drying
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • 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
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/08—Reinforcements
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/22—Fibres of short length
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/51—Elastic
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1043—Subsequent to assembly
    • Y10T156/1044—Subsequent to assembly of parallel stacked sheets only
    • Y10T156/1048—Subsequent to assembly of parallel stacked sheets only to form dished or receptacle-like product
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249923—Including interlaminar mechanical fastener
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249981—Plural void-containing components
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/674—Nonwoven fabric with a preformed polymeric film or sheet

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Laminated Bodies (AREA)
  • Reinforced Plastic Materials (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Description

Foreliggende oppfinnelse angår en fremgangsmåte for fremstilling av laminerte, armerte, termoplastiske art fra termoplastiske ark som kan være forskjellige eller inkompatible.
I EP-A3 0148761 beskrives en fremgangsmåte for fremstilling av fiberarmerte plastmaterialer. Det er funnet at ark av denne type som huser forskjellige typer termoplastisk materiale er vanskelige å laminere hvis de er konsolidert. Det er imidlertid oppdaget at det er mulig å fremstille et slikt laminat hvis utgangsarkene ikke er konsolidert, for eksempel som beskrevet i EP-A3 0148760, eller er ekspandert fra konsolidert tilstand som beskrevet i EP-Å3 0148763.
Av kjent teknikk skal det henvises til EP-A3 0148761 som beskriver et fast, fiberarmert plastmateriale, inneholdende 20 til 60 vekt-5é diskrete armeringsf ibre med en spesiell elastisitetsmodul og der fibrene har en spesiell lengde og en diameter på 13 pm eller mindre. Det er imidlertid funnet at ark av denne type som huser forskjellige typer termoplastisk materiale, er vanskelige å laminere hvis de er konsolidert.
Det er imidlertid oppdaget at det er mulig å fremstille et slikt laminat hvis utgangsmaterialene ikke er konsolidert, for eksempel som beskrevet i EP-A33 0148760 som beskriver en fremgangsmåte for fremstilling av permeable ark lik fibrøse strukturer med en bane på 20 til 60 % fibre, imidlertid beskrives ingen sammenbinding av to sjikt av et slikt materiale ved bruk av forskjellige, inkompatible termoplastiske materialer.
Videre er det oppdaget at det er mulig å fremstille et laminat som antydet ovenfor hvis utgangsarkene er ekspandert fra konsolidert tilstand som beskrevet i EP-A3 0148763 som beskriver en fremgangsmåte for fremstilling av en støpt porøs gjenstand med 20 til 70 vekt-# glassarmerende fibre av spesiell lengde men som angår den spesielle prosess som omfatter avsetning av en dispersjon av materialet på en foraminøs bærer. Fibrene tillates så å ekspandere for å danne et porøst ark.
Denne prosess kan også benyttes ved fremstilling av ark før laminering men det er ingen beskrivelse om laminering av ark fra forskjellige og inkompatible, termoplastiske materialer.
Av annen kjent teknikk skal det henvises til US-A1.4.555.426 som antyder ideen om å tildanne et fiberarmert laminat fra et antall utgangsark. Selv om imidlertid et vidt spektrum termoplastiske harpikser er anført, antydes det intet sted om at komponentarkene som benyttes for å fremstille laminatet omfatter forskjellige, termoplastiske materialer.
US-A1 1.519.310 krever at de termoplastiske materialer i to sjikt er i stand til kopolymerisering. Som sådanne er derfor de to harpikser ikke inkompatible idet det vil dannes en kjemisk binding mellom dem.
Til slutt skal det henvises til GB-Al 1.373.782 som beskriver fremstilling av armerte plaster av den type som omfatter syntetiske harpikser av enten termoherdende eller termoplastisk type, armert med sjikt av fibrøst materiale, for eksempel matter av glassfibre, og til DE-A1 2.113.714 som beskriver matteformede armeringsmaterialer for fiberarmerte harpikser, bestående av minst en fibermatte der fibrene eller strengene er fritt bevegelige mot hverandre. Heller ikke disse beskriver laminering av materialer som er forskjellige fra og inkompatible med hverandre.
Foreliggende oppfinnelse har således til hensikt å forbedre den kjente teknikk og angår en fremgangsmåte for fremstilling av laminerte, armerte, termoplastiske ark omfattende tildanning av første (A) og andre (B) ark som hver omfatter 20 til 60 vekt-# adskilte, diskrete armerende fibre med lengde mellom 7 og 50 mm og en diameter < 13 pm og med en elastisitetsmodul på over 10 000 MPa og 40 til 60 vekt-# termoplastisk materiale og samtidig eller sekvensielt å legge på varme og trykk for å bringe arkene til konsolidering og adhesjon til hverandre under dannelse av et laminat, og denne fremgangsmåte karakteriseres ved at det anvendes første (A) og andre (B) ark som er ikke-konsoliderte og/eller porøse før laminering idet det termoplastiske materialet i det først ark (A) er forskjellig fra og inkompatibelt med det termoplastiske materiale i det andre ark (B).
Porøsitetsinnholdet i arket kan være inherent i den ikke-konsoliderte tilstand av utgangsarket eller genereres ved ekspandering av et konsolidert ark.
Fibrene foreligger i form av enkelte diskrete glassfibre. Slike fibre tilveiebringes vanligvis sammen i opphakkede strengbunter og disse må brytes ned til enkelte fibre før arkene tildannes.
Da fibrene nødvendigvis må være overensstemmende med strukturelle styrker i laminatet bør de diskrete glassfibre ikke være kortere enn ca. 7 mm eller ha en diameter større enn 13 pm fordi slike fibre som er lengre ikke lenger adekvat armerer plastmatriksen og fibre som har større diameter armerer ikke matriksen effektivt. Fordi fibre av andre stoffer med en armerende effektivitet i det minste like høy som glassfibre kan disse alternativt benyttes.
Med høy elastisitetsmodul menes en elastisitetsmodul som er vesentlig høyere enn den til arket. Fibre som faller inn i denne kategori inkluderer glass-, karbon- og keramiske fibre og fibre som de aramidfibre som er kommersielt tilgjengelige under betegnelsen "Kevlar" og "Nomex" og vil vanligvis inkludere enhver fiber med en modul høyere enn 10.000 Mega Pascal.
Som nevnt ovenfor kan arkene først konsolideres og derefter ekspanderes ved pålegging av varme før laminering. I en alternativ metode kan de ikke-konsoliderte ark tildannes og tørkes samtidig med lamineringen.
De termoplastiske materialer kan for eksempel være av typen polyetylen, polypropylen, polystyren, acrilonitrystyren-butadien, polyetyleneterftalat, polybutyleneterftalat eller polyvinylklorid, både mykgjorte og ikke-mykgjorte, eller legeringer eller blandinger av disse stoffer med hverandre eller andre polymerstoffer. Andre egnede termoplaster omfatter polyetyleneter, polykarbonater, polyesterkarbonater, termoplastiske polyestere, polyeterimider eller akrylnitril-butylakrylat - styrenpolymerer eller amorfe nylon- eller polyaryleneter keton eller legeringer eller blandinger av disse med hverandre eller andre polymermaterialer.
Oppfinnelsen kan gjennomføres på mange måter og enkelte utførelsesformer skal beskrives eksempelvis under henvisning til de ledsagende tegninger der: Fig. 1 viser en fremgangsmåte for forening av ark til et laminat som kun gir dårllig adhesjon; Fig. 2 viser en fremgangsmåte for fremstilling av et laminat i henhold til oppfinnelsen; Fig. 3 viser en alternativ metode;
Fig. 4 viser en ytterligere alternativ metode; og
Fig. 5 viser en metode for fremstilling av en gjenstand som benytter laminatet som fremstilles ifølge oppfinnelsen.
I de følgende eksempler blir de porøse ark A og B fremstilt med en totalvekt på 2.000 g/m<2>, hver i henhold til den metode som er angitt i EP-publ. 0148761, idet hvert ark inneholdt 25 vekt-# glassfibre med diameter 11 pm og lengde 13 mm, dog dispergert i forskjellige termoplastiske materialer. Ark A som vist i tegningene ble tildannet ved hjelp av polypropylen av kvalitet GY545M mens ark B besto av "XENOY", en termoplastisk legering av polykarbonat og polybutylentereftalat. Laminatene ble fremstilt på fire forskjellige måter som vist i de ledsagende tegninger. Adhesjonen mellom sjiktene ble bedømt subjektivt ved oppskjæring av en strimmel med bredde 15 mm og lengde 200 mm og å tvinne denne ende i motsatt retning inntil det enten skjedde delaminering eller tverr-brudd.
Eksempel 1 (Kontroll)
Som vist i Fig. 1 ble ikke-konsoliderte tørre ark A og B som fremstilt i EP-publ. 0148760 individuelt varmpresset ved henholdsvis 190 og 260°C og avkjølt for derved å gi koldkonsoliderte ark 1 og 2. Disse koldkonsoliderte ark A og B ble så varmpresset sammen i en presse 3 ved 1379 x 10^ Pa idet temperaturen i pressplatene i kontakt med arkene var henholdsvis 170 og 250°C. Det resulterende laminat 4 ble avkjølt og ved prøving ble det funnet å ha meget dårlig adhesjon mellom komponentarkene.
Eksempel 2
Som vist i Fig. 2 ble arkene A og B som på forhånd var konsolidert oppvarmet og ekspandert på den måte som er beskrevet i EP-publ. 0148763 slik at de ble permeable som antydet under henvisning til referansetallene 5 og 6. De ekspanderte ark ble anbragt sammen i en presse 3 der de ble underkastet et trykk på 1379 x 10^ Pa ved en temperatur på 90° C. Det resulterende laminat ble avkjølt og adhesjonen mellom komponentarkene ble funnet å være bedre enn i den metode beskrevet under henvisning til Fig.l.
Eksempel 3.
Som vist i Fig. 3 ble ikke-konsoliderte ark A og B av den type som ble benyttet ved starten i Eks. 1 anbragt sammen i en presse 3 der de ble underkastet et trykk på 1379 x 10<3>Pa med pressflåtene på en temperatur på 170 henholdsvis 250°C. Dét resulterende laminat ble tillatt avkjøling og det ble funnet at det var meget god adhesjon mellom komponentarkene.
Eksempel 4.
Som vist i Fig. 4 ble ikke-konsoliderte tørrark A og B av den typen som ble brukt i Eks. 1 tildannet og tørket sammen før de ble anbragt i varmpressen der de ble underkastet den samme behandling som i Eks. 3. Man oppnådd meget god adhesjon mellom komponentarkene.
Eksempel 5.
Fig. 5 viser en metode for fremstilling av en gjenstand via et laminat 8 fremstilt i henhold til fremgangsmåten ifølge Eks. 3. Laminatet 8 anbringes i en egnet oppvarmet tildann-ingsform 9 i en presse 10 hvis to plater oppvarmes til 90° C og derefter underkastes et trykk på 1379 x 10<3>Pa for å gi en støpt gjenstand 11.
Avhengig av det benyttede materiale kan sluttbehandlingen av laminatet eller den støpte gjentand variere. Hvis således arket A har et relativt lavt glassfiberinnhold på for eksempel 25% vil den nedre overflate 12 av den fremstilte gjenstand tildannes med en relativt glatt finish. På den annen side vil et høyt glassfiberinnhold på for eksempel 60$ resultere i en porøs overflate som gir en nøkkel for et overflatesjikt som derefter kan påføres.
Oppfinnelsen finner anvendelse ved teknikker for fremstilling av støpte gjenstander fra et laminat som for eksempel kan ha et varmemotstandsdyktig sjikt på en side og et lett formbart sjikt på den annen side fremstilt fra en mindre kostbar termoplast. Det skal påpekes at oppfinnelsen også gjelder dannelsen av laminater med mer enn to sjikt. For eksempel kan det tilveiebringes et tresjikstlaminat med et kjernesjikt av fiberforsterket polypropylen og overflatesjikt av fiberforsterket nylon.
I de følgende eksempler blir en skive med diameter på 22 cm, fremstilt av et glassmatte/polypropylenlaminat med en vekt på 4.000 g/m<2> og et glassf iberinnhold på 40, kommersielt tilgjengelig under betegnelsen "AZDEL", oppvarmet til 205°C i 7 1/2 min. i en ovn og laminert i en skivetildannet form under et trykk på 1379 x 10<3>Pa.
Eksempel 6.
Den andre komponent i laminatet omfattet et porøst ikke-konsolidert arklignende materiale med en vekt på 3.000 g/m<2>, fremstilt som beskrevet i EP-publ. 0148760 fra 30% glassfibre med lengde 12 mm og diameter 11 pm og 70% nylon 6 pulver av typen "MARANYL 236R". Det resulterende laminat viste god adhesjon mellom sjiktene efter avkjøling.
Eksempel 7.
Den andre komponent av laminatet var i det vesentlige den samme som i Eks. 6 bortsett fra at det termoplastiske innhold omfattet 70$ av en termoplastisk legering av polykarbonat og polybutylen tereftalat av typen "VALOX".
Det resulterende laminat viste god adhesjon mellom sjiktene efter avkjøling.

Claims (2)

1. Fremgangsmåte for fremstilling av laminerte, armerte, termoplastiske ark omfattende tildanning av første (A) og andre (B) ark som hver omfatter 20 til 60 vekt-$ adskilte, diskrete armerende fibre med lengde mellom 7 og 50 mm og en diameter < 13 pm og med en elastisitetsmodul på over 10 000 MPa og 40 til 60 vekt-# termoplastisk materiale og samtidig eller sekvensielt å legge på varme og trykk for å bringe arkene til konsolidering og adhesjon til hverandre under dannelse av et laminat, karakterisert ved at det anvendes første (A) og andre (B) ark som er ikke-konsoliderte og/eller porøse før laminering idet det termoplastiske materialet i det først ark (A) er forskjellig fra og inkompatibelt med det termoplastiske materiale i det andre ark (B).
2 . Fremgangsmåte ifølge krav 1, karakterisert ved at minst et av arkene (A, B) fremstilles fra ark som på forhånd er konsolidert og som derefter ekspanderes ved anvendelse av varme for å gjøre det ikke-konsolidert og å gjøre det porøst før laminering.
NO873138A 1986-07-31 1987-07-27 Fremgangsmåte for fremstilling av laminerte forsterkede termoplastiske ark NO174770C (no)

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FI873262A (fi) 1988-02-01
DK389587D0 (da) 1987-07-27
ATE86543T1 (de) 1993-03-15
US5639324A (en) 1997-06-17
CA1299480C (en) 1992-04-28
DE3784580T2 (de) 1993-06-17
JP2539228B2 (ja) 1996-10-02
AU607926B2 (en) 1991-03-21
DK164027C (da) 1992-09-28
GB8618727D0 (en) 1986-09-10
NO873138D0 (no) 1987-07-27
DK389587A (da) 1988-02-01
FI92303C (fi) 1994-10-25
FI92303B (fi) 1994-07-15
US4957805A (en) 1990-09-18
NO873138L (no) 1988-02-01
IE872027L (en) 1988-01-31
KR880001431A (ko) 1988-04-23
PT85416A (pt) 1988-07-29
IE59731B1 (en) 1994-03-23
DK164027B (da) 1992-05-04
DE3784580D1 (de) 1993-04-15
BR8703883A (pt) 1988-03-29
EP0255315B1 (en) 1993-03-10
PT85416B (pt) 1994-11-30
EP0255315A3 (en) 1989-11-29
ZA875503B (en) 1988-02-01
NO174770C (no) 1994-07-06
FI873262A0 (fi) 1987-07-27
AU7614287A (en) 1988-02-04
ES2053546T3 (es) 1994-08-01
EP0255315A2 (en) 1988-02-03
JPS6337907A (ja) 1988-02-18
KR950012800B1 (ko) 1995-10-21

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