US20110151231A1 - Reinforcement textile armature and method for making same - Google Patents

Reinforcement textile armature and method for making same Download PDF

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Publication number
US20110151231A1
US20110151231A1 US12/599,524 US59952408A US2011151231A1 US 20110151231 A1 US20110151231 A1 US 20110151231A1 US 59952408 A US59952408 A US 59952408A US 2011151231 A1 US2011151231 A1 US 2011151231A1
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fiber sections
chopped
chemical fiber
textile
central layer
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Gilbert Chomarat
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • 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
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • 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
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • 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
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4282—Addition polymers
    • D04H1/4291—Olefin series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4391—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres
    • D04H1/43918—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres nonlinear fibres, e.g. crimped or coiled fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/485—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
    • 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

Definitions

  • the present invention concerns textile armatures used as products for reinforcing composite articles, i.e. articles based on resin (polyester or other resin) reinforced by a reinforcement textile armature.
  • Reinforcement textile armatures are known from the document EP 0 395 548 which describes the use of two textile reinforcement layers disposed on opposite sides of a central layer consisting of a mat based on fibers with permanent undulations. The reinforcement textile layers and the central layer are stitched/knitted together.
  • the document EP 0 694 643 for its part describes a textile armature used to produce composite articles and consisting of at least two reinforcement textile layers as such disposed on opposite sides of a central layer providing the thickness of said material, said layers being stitched/knitted together, which armature includes against at least one of its external faces a synthetic fiber veil, said veil being attached either by gluing it to the outside of the complex or by stitching the various layers together.
  • Stitching/knitting techniques are relatively slow and lead to slow fabrication rates, of the order of 3 to 5 meters per minute, that cannot be speeded up.
  • the textile armatures of the above documents also have non-uniform deformation capacities over their surface because of the use of stitching/knitting means to fasten the various textile layers to each other.
  • the presence of stitching/knitting rows induces surface appearance defects in the finished part obtained after impregnating the textile armature with resin.
  • the document EP 0 659 922 discloses the use of two reinforcement textile layers disposed on opposite sides of a central layer consisting of a mat based on fibers with permanent undulations with, on at least one of the reinforcement textile layers, a fibrous veil based on chemical fibers with permanent crimping and with a linear density lower than that of the fibers of the central layer.
  • the fibrous veil or veils, the reinforcement textile layers and the central layer are needle-punched together.
  • the needle-punching technique is still slow, leading to fabrication rates of the same order as the stitching/knitting technique. Also, the connection between the layers of the armature is often insufficient.
  • a first problem addressed by the invention is providing a textile armature that is of relatively low cost because it is quick to fabricate and that has good multidirectional deformation capacities when used to produce composite materials or parts.
  • the present invention seeks to provide a textile armature that can be impregnated with resin easily and homogeneously when using press molding, injection molding or vacuum molding techniques.
  • Another aspect of the invention seeks to provide a textile armature of the above kind that can be easily cut without fraying.
  • the invention proposes a textile armature usable for the production of composite materials or parts, comprising:
  • Such a textile armature has good deformation capacities in a number of directions. More particularly, such an armature has no preferential deformation direction and no direction in which deformation is prevented.
  • the textile armature of the invention has homogeneous cohesion between its various textile layers in all directions.
  • the chemical fibers adhere to the textile armature central layer fibers that they penetrate, it is possible to ensure efficacious interconnection of the armature layers by means of a relatively small number of such chemical fibers penetrating the central layer.
  • the penetration of a relatively small number of chemical fibers can then be achieved using a preliminary needle-punching or light needle-punching technique, consisting of less dense needle-punching. Preliminary needle-punching is much faster than knitting/stitching and avoids breaking the reinforcement fibers, especially when they are glass fibers.
  • the permanent crimp of the chopped fiber sections of the central layer allows easy deformation of the textile armature when used in molding techniques. Moreover, the permanent crimp of the chopped fiber sections of the central layer preserves free spaces between the chopped fiber sections, thus conferring an aerated character on the armature, which encourages flow of resin when using press molding, injection molding or vacuum molding techniques.
  • the adhesion to each other of the chopped chemical fiber sections in the external layers efficiently limits the risk of fraying of the textile armature when cut. Avoided in particular is fraying of chopped glass fiber sections that reinforce the textile armature.
  • the chemical fibers have a permanent crimp enabling homogeneous external layers to be produced from a homogeneous mixture of chopped reinforcement fiber sections and chopped chemical fiber sections, for example.
  • the crimp of the chemical fibers avoids “settling” of the mixture of fibers because of their different relative densities or sections.
  • a homogeneous mixture can thus be obtained leading to the production of homogeneous external layers: in the external layers, the chemical fibers and the reinforcement fibers are then mixed in a generally homogeneous manner.
  • the reinforcement fibers can be glass fibers or plant (hemp, sisal, flax, etc.) fibers.
  • the chopped fiber sections of the central layer can preferably be of polypropylene, polyester or polyamide. This is because these fibers are very widely used in the textile industry, of relatively low cost, easy to spin and easy to shape to produce chopped fiber sections with an elastic permanent crimp.
  • the chopped fiber sections of the central layer can have at least two different unitary linear densities.
  • the chopped chemical fiber sections present in the external layers advantageously have a cross section of smaller diameter than the chopped reinforcement fiber sections.
  • This diameter difference encourages entrainment and penetration along at least part of the length of at least some of the chopped chemical fiber sections of the external layers into the central layer by a preliminary needle-punching process.
  • the needles chosen to entrain the chopped chemical fiber sections have a small cross section, so that they do not entrain the chopped reinforcement fiber sections much, if at all. This prevents breaking of the fragile chopped reinforcement fiber sections that reinforce the textile armature, specially in the case of reinforcing glass fibers.
  • the first chopped chemical fiber sections of the external layers can advantageously be of a thermoplastic material with a melting point lower than that of the chopped fiber sections of the central layer.
  • the first chopped chemical fiber sections of the external layers can be of polyethylene.
  • Polyethylene is a material very widely used in the textile industry, of relatively low cost and having a low melting point. It provides thermal bonding at lower energy cost.
  • the external layers can advantageously be produced in a stratified form, comprising an external stratum essentially of chopped chemical fiber sections, an internal stratum essentially of chopped chemical fiber sections, and an intermediate stratum essentially of reinforcement fibers.
  • the connection between the strata is provided by preliminary needle-punching followed by surface softening of the first chopped chemical fiber sections, some chemical fibers of the external stratum passing through the intermediate and internal strata of the external layer to penetrate into the central layer of the textile armature.
  • the exterior surface of the textile armature consists essentially of chemical fibers.
  • the thermoplastic material surface layers of these chemical fibers adhere to each other and thus oppose fraying of or damage to the reinforcement fibers upon subsequent handling of the textile armature when not yet embedded in resin.
  • the chopped chemical fiber sections of the external layers can include only first chopped chemical fiber sections.
  • the chopped chemical fiber sections of the external layers can include a mixture of first chopped chemical fiber sections and second chopped chemical fiber sections.
  • the second chopped chemical fiber sections are of a material having a melting point higher than the melting point of the thermoplastic material of the first chopped chemical fiber sections and a price very much lower than the price of the chemical fibers from which the first chopped chemical fiber sections are fabricated.
  • the chopped second chemical fiber sections are of polyamide or polyester.
  • Another aspect of the invention proposes a method of fabricating a textile armature usable for the production of composite materials or parts, including the following successive steps:
  • Such a fabrication process is easy to implement with technical means (machines, tooling, etc.) known and very widely used in the textile industry.
  • the process is therefore of relatively low cost.
  • the use of thermal bonding also allows a higher production rate than using bonding by stitching/knitting or by needle-punching.
  • the heating can preferably be obtained by circulating hot air through the textile armature.
  • This heating method provides thermal bonding of the fibers to each other as far as the heart of the textile armature and avoids intensive heating of the lower and upper faces of the textile armature on which are disposed the external layers including chopped chemical fiber sections. This therefore avoids excessive melting of the chopped chemical fiber sections of the external layers and the formation of a continuous layer of thermoplastic material after cooling, which continuous layer would compromise good impregnation of the textile armature by the resin on its use in press molding, injection molding or vacuum molding techniques.
  • the heating can be effected by high-frequency microwave radiation or by infrared radiation of appropriate wavelength to soften the first chopped chemical fiber sections.
  • FIG. 1 is a diagrammatic view in longitudinal section of a textile armature of a first embodiment of the invention during its fabrication
  • FIG. 2 is a diagrammatic view in longitudinal section of the FIG. 1 textile armature during a preliminary needle-punching operation
  • FIG. 3 is a diagrammatic view in longitudinal section of the FIG. 2 textile armature during a heating operation
  • FIG. 4 shows in perspective a chopped chemical fiber section of a two-component structure
  • FIG. 5 is a diagrammatic view in longitudinal section of a textile armature of a second embodiment of the invention.
  • a textile armature 1 of the invention includes three successive textile layers 21 , 3 and 22 .
  • the central layer 3 is based on chopped fiber sections 3 a of a first type of synthetic material.
  • the chopped fiber sections 3 a have been treated to confer a permanent crimp on them before they are formed into a layer.
  • the latter chopped fiber sections can advantageously be fabricated from single-strand fibers.
  • the chopped fiber sections 3 a can have the same unitary linear density. It is nevertheless possible for the chopped fiber sections 3 a to have at least two different unitary linear densities for greater regularity of the central layer 3 .
  • the central layer 3 can include chopped fiber sections 3 a of 110 dTex and chopped fiber sections 3 a of 70 dTex, for example.
  • the external textile layers 21 and 22 are based on a mixture of chopped reinforcement fiber sections 4 and chopped chemical fiber sections 7 .
  • the chopped chemical fiber sections 7 have been treated beforehand to confer a permanent crimp on them.
  • the external textile layers 21 and 22 are obtained from a homogeneous mixture of chopped chemical fiber sections 7 and chopped reinforcement fiber sections 4 such as glass fibers or plant fibers. Such a homogeneous mixture can be obtained by means of an appropriate cutter and then will be deposited by gravity onto the two faces of the central layer 3 .
  • the homogeneity of the mixture is also a result of the permanent crimp of the chopped chemical fiber sections 7 , which imparts a “grab” to the mixture and prevents a phenomenon known as “settling” caused by the different relative densities or sections of the chopped reinforcement fiber sections 4 and the chopped chemical fiber sections 7 .
  • the chopped chemical fiber sections 7 of the external textile layers 21 and 22 include at least first chopped chemical fiber sections 70 in a thermoplastic material having a melting point less than or equal to that of the chopped fiber sections 3 a of the central layer 3 .
  • the textile armature 1 has no secure cohesion or connection allowing it to be transported.
  • the textile armature 1 undergoes a preliminary needle-punching treatment shown in FIG. 2 .
  • needles 8 cause at least some of the chopped chemical fiber sections 7 (including the first chopped chemical fiber sections 70 ) of each external textile layer 21 and 22 to penetrate over part of their length into the central layer 3 .
  • the direction of movement of the textile armature 1 is indicated by the arrow 12 and the direction of movement of the needles is perpendicular to that direction 12 and to the surface of the textile armature 1 .
  • the needles 8 used have barbs 8 a of appropriate size for preferential entrainment of the chopped chemical fiber sections 7 , and in particular the first chopped chemical fiber sections 70 , and do not entrain the chopped reinforcement fiber sections 4 of the external textile layers 21 and 22 .
  • the chopped chemical fiber sections 7 in particular the first chopped chemical fiber sections 70 , have a smaller diameter than the chopped reinforcement fiber sections 4 .
  • chopped chemical fiber sections 7 of approximately 2 to 6 denier and chopped reinforcement fiber sections 4 of approximately 40 Tex minimum are used.
  • the thicknesses and dimensions of the lines representing the chopped fiber sections 3 a , 4 , 7 and 70 in FIGS. 1 to 3 are not representative of the actual thicknesses and dimensions of the chopped fiber sections 3 a , 4 , 7 and 70 .
  • the thicknesses and dimensions used in FIGS. 1 to 3 are merely intended to make it easier for the reader to appreciate the difference between the various fibers 3 a , 4 , 7 and 70 and textile layers 21 , 3 and 22 .
  • Preliminary needle-punching differs from needle-punching in that the textile armature 1 is passed between the needles 8 at a higher speed and the density of the needles 8 is lower.
  • standard needle-punching achieves a fabrication rate of at most approximately 4 meters per minute
  • preliminary needle-punching achieves a rate of between approximately 8 meters per minute and approximately 20 meters per minute.
  • a needle-punching machine conventionally has a needle density per running meter between approximately 1600 and 32000
  • a preliminary needle-punching machine has a needle density per running meter between approximately 900 and 1400.
  • the low needle density per running meter limits the risk of the chopped reinforcement fiber sections 4 of the textile layers 21 and 22 breaking when the needles 8 cause some of the chopped chemical fiber sections 7 to penetrate the external layers 21 and 22 in the central layer 3 , especially in the case of reinforcement glass fibers 4 .
  • the preliminary needle-punching is sufficient to ensure cohesion during transfer of the textile armature blank to the next workstation but insufficient to provide the final cohesion of the textile armature 1 , which is still not transportable to use as a reinforcing product following preliminary needle-punching.
  • the textile armature 1 is heated ( FIG. 3 ). During this heating step, the thermoplastic surface layer of the first chopped chemical fiber sections 70 of the external textile layers 21 and 22 is softened and renders the first chopped chemical fiber sections 70 adherent. The first chopped chemical fiber sections 70 that have been entrained by the preliminary needle-punching needles 8 adhere to the adjacent chopped reinforcement fiber sections 4 of the external textile layers 21 and 22 and adhere to the adjacent chopped fiber sections 3 a of the central layer 3 . After cooling, the various textile layers 21 , 3 and 22 of the textile armature 1 are thus interconnected by needle-punched and adhesively bonded fibers of the at least partly thermoplastic first chopped chemical fiber sections 70 .
  • the textile armature 1 can then be transported.
  • the adhesion of the at least partly thermoplastic first chopped chemical fiber sections 70 to the chopped reinforcement fiber sections 4 of the external textile layers 21 and 22 and to the chopped fiber sections 3 a of the central layer 3 compensates the inability of preliminary needle-punching to ensure sufficient cohesion of the textile armature 1 to render it transportable.
  • the chopped fiber sections 3 a of the central layer 3 can be of polypropylene.
  • Polypropylene is easy to spin and easy to shape to produce chopped fiber sections with permanent elastic crimp.
  • Chopped fiber sections 3 a in polyester or in polyamide can equally be used.
  • the chopped chemical fiber sections 7 include first chopped thermoplastic polyethylene fiber sections 70 .
  • First thermoplastic chopped chemical fiber sections 70 of any other material having a melting point lower than that of the chopped fiber sections 3 a of the central layer 3 can equally be used.
  • polyethylene is advantageous because of its low melting point.
  • the chopped polypropylene, polyester or polyamide fiber sections 3 a of the central layer 3 are not damaged much, if at all, by the heating operation and in this case retain all their physical and technical characteristics.
  • the first chopped chemical fiber sections 70 of polyethylene drawn by preliminary needle-punching into the external textile layers 21 and 22 are softened by heating and adhere to the adjacent fibers of the textile layers 21 and 22 and to each other.
  • Heating is adjusted to soften and render the thermoplastic first chopped chemical fiber sections 70 adherent, but without melting them. This avoids the formation of uniform exterior layers on the upper and lower faces of the textile armature 1 that are impermeable to the resin. Such uniform and impermeable layers would compromise good impregnation of the textile armature 1 by the resin during a subsequent step of shaping by press molding, injection molding or vacuum molding.
  • thermoplastic fibers can be used as the first chopped chemical fiber sections 70 , as shown in FIG. 4 , having a central core 7 a and an external sheath 7 b , the melting point of the central core 7 a being higher than that of the external sheath 7 b.
  • the two-component first chopped chemical fiber sections 70 can include a polyamide, polyester or polypropylene central core 7 a and an external sheath 7 b of copolyester, polyethylene or any other material having a melting point less than that of the chopped fiber sections 3 a of the central layer 3 .
  • good results have been obtained using a central core of polyester and an external sheath of copolyester or a central core of polypropylene and an external sheath of polyethylene.
  • Other pairs of materials can be used in the form of coaxial two-component fibers: polypropylene and copolypropylene; polypropylene and ethyl vinyl acetate.
  • the central core 7 a has a higher melting point than the external sheath 7 b , the risk of accidental complete melting of the thermoplastic first chopped chemical fiber sections 70 of the external textile layers 21 and 22 during fabrication of the textile armature 1 is avoided.
  • thermoplastic first chopped chemical fiber sections 70 being completely melted by excessive or poorly controlled heating, forming uniform layers impermeable to the resin by spreading of their constituent material over the upper and lower faces of the textile armature 1 .
  • the core of the two-component fibers is not damaged much, if at all: thus the external textile layers 21 and 22 are not damaged.
  • thermoplastic first chopped chemical fiber sections 70 with an external sheath 7 b and a central core 7 a reduces the polyolefin content of the textile armature 1 .
  • the resin being not particularly compatible with polyolefins. In fact, the resin adheres badly to polyolefin fibers.
  • the two-component thermoplastic first chopped chemical fiber sections 70 can advantageously have an external sheath 7 b of copolyester or polyethylene.
  • the chopped polypropylene, polyester or polyamide fiber sections 3 a of the central layer 3 are thus not affected by heating.
  • copolyester and polyethylene have melting points lower than those of polypropylene, polyester or polyamide. It is then possible to heat the textile armature 1 to a temperature just sufficient to soften the copolyester or polyethylene of the two-component thermoplastic first chopped chemical fiber sections 70 without softening or otherwise affecting the polypropylene, polyester or polyamide chopped fiber sections 3 a of the central layer 3 .
  • a textile armature 1 of the invention again includes three textile layers 21 , 3 and 22 in succession.
  • the central layer 3 has the same structure as the central layer 3 of the FIG. 1 embodiment described above.
  • the difference lies in the structure of the external layers 21 and 22 .
  • the external layers 21 and 22 are stratified layers each comprising a respective external stratum 21 c or 22 c , a respective internal stratum 21 a or 22 a and a respective intermediate stratum 21 b or 22 b.
  • the external strata 21 c and 22 c and the internal strata 21 a and 22 a consist essentially of chopped sections of chemical fibers such as the chemical fibers 7 of the FIG. 1 embodiment (which include at least first chopped chemical fiber sections 70 including at least one thermoplastic material surface layer).
  • the intermediate strata 21 b and 22 b consist essentially of reinforcement fibers such as the reinforcement fibers 4 of the FIG. 1 embodiment.
  • chopped chemical fiber sections 7 including first chopped chemical fiber sections 70 , are drawn through the strata by the needles until they penetrate into the central layer 3 .
  • an internal stratum 21 a , 22 a can be omitted.
  • the textile armature 1 of the invention can easily be fabricated at low cost by a method including the following steps in succession:
  • step d) of heating the textile armature 1 there can advantageously follow a step e) of cold-rolling the textile armature 1 to give it a constant and homogeneous thickness. Rolling also encourages compacting of the fibers and bonding of the fibers to each other.
  • the chopped chemical fiber sections 7 of the external layers 21 and 22 , and in particular the first chopped chemical fiber sections 70 can advantageously have a diameter less than that of the chopped reinforcement fiber sections 4 .
  • the preliminary needle-punching of the step c) is then effected by means of needles 8 ( FIG. 2 ) that have barbs 8 a adapted to entrain preferentially the chopped chemical fiber sections 7 , including the first chopped chemical fiber sections 70 , but not to entrain significantly the greater diameter chopped reinforcement fiber sections 4 .
  • the textile armature 1 enters a hot-air tunnel oven 9 .
  • the hot-air tunnel oven 9 includes a conveyor belt 11 that moves the textile armature 1 through the oven 9 in the direction defined by the arrow 13 .
  • the conveyor belt 11 is perforated.
  • Hot air jets 14 are directed through the textile armature 1 to heat it throughout its thickness in order to cause the first chopped chemical fiber sections 70 which are at least in part of the thermoplastic type to adhere to the chopped fiber sections 3 a of the central layer 3 and to the chopped reinforcement fiber sections 4 of the external layers 21 and 22 .
  • a homogeneous mixture of chopped chemical fiber sections 7 and chopped reinforcement fiber sections 4 is obtained by means of a cutter during the step b) and deposited by gravity onto the two faces of the central layer 3 .
  • the chemical fiber strata 21 a , 22 a , 21 c and 22 c are each produced by carding.
  • the internal strata 21 a and 22 a if any, are disposed on either side of the central layer 3 , after which the intermediate strata 21 b and 22 b of reinforcement fibers cut by a cutter are deposited by gravity, after which the external strata 21 c and 22 c are disposed on either side of the assembly formed in this way.
  • the chopped chemical fiber sections 7 of the external layers 21 and 22 can consist only of first chopped chemical fiber sections 70 .
  • the chopped chemical fiber sections 7 of the external layers 21 and 22 can consist of a mixture of first chopped chemical fiber sections 70 and second chopped chemical fiber sections 71 .
  • the second chopped chemical fiber sections 71 are chosen to have a melting point higher than that of the first chopped chemical fiber sections 70 and are of a material less costly than the material of the first chopped chemical fiber sections 70 .
  • Second chopped chemical fiber sections 71 of polyester or polyamide could be used, for example.
  • first chopped chemical fiber sections 70 and second chopped chemical fiber sections 71 significantly reduces the fabrication cost of the textile armature of the invention.
  • a mixture containing approximately 50% to 70% by weight of second chopped chemical fiber sections 71 can be used.
  • thermoplastic material in the external layers 21 and 22 reduces the quantity of thermoplastic material in the external layers 21 and 22 to avoid, after the heating step, forming on the surface of the textile armature 1 an impermeable film of thermoplastic material preventing penetration of the resin, whilst conferring on the mixture, thanks to the second chopped chemical fiber sections 71 , sufficient density to be carded by a conventional carding device.
  • the textile armature 1 of the invention in particular its variant with a mixture of first chopped chemical fiber sections 70 and second chopped chemical fiber sections 71 , has proven to be of remarkable benefit in so-called “pre-forming” techniques.
  • the textile armature 1 is heated during the step d) of the fabrication process that conforms it to a required shape. It is heated just sufficiently for the shape obtained to be able to be transported to a resin injection molding machine with a mold corresponding to the shape obtained and enabling the textile armature to be heated again, and slightly more strongly, before or during injection of the resin.
  • a central layer 3 is produced of chopped crimped monofilament fiber sections 3 a of polypropylene with a unitary linear density of 110 dTex.
  • the chopped fiber sections 3 a have a cut length of approximately 90 mm, a crimp of approximately two undulations per centimeter, and a melting point between approximately 170° C. and 180° C.
  • the central layer 3 has a mean thickness between approximately 4 and 5 mm and a weight of approximately 250 grams per square meter.
  • chopped crimped monofilament polypropylene fiber sections 3 a with a unitary linear density of 70 dTex can be mixed in a proportion from 10% to 50% by weight with chopped fiber sections 3 a having a unitary linear density of 110 dTex.
  • the chopped chemical fiber sections 7 consist of a mixture comprising 70% (by weight) of second chopped crimped chemical fiber sections 71 of polyester and 30% (by weight) of two-component first chopped chemical fiber sections 70 .
  • the two-component first chopped chemical fiber sections 70 have a central core 7 a of polyester and a thermoplastic external sheath 7 b of copolyester.
  • the thermoplastic copolyester external sheath 7 b has a melting point of approximately 110° C.
  • the second chopped crimped chemical fiber sections 71 of polyester have a unitary linear density between approximately 3 denier and approximately 6 denier, preferably chosen to be approximately 3.5 denier.
  • the two-component first chopped chemical fiber sections 70 have a unitary linear density between approximately 2 denier and 4 denier.
  • each internal stratum 21 a and 22 a there is deposited on each internal stratum 21 a and 22 a an intermediate stratum 21 b and 22 b consisting of chopped reinforcement fiber sections 4 .
  • the chopped reinforcement fiber sections 4 are chopped glass fiber sections 4 having a unitary linear density of approximately 50 Tex and a cut length of approximately 50 mm.
  • the diameter of the elementary fibers of the chopped glass fiber sections 4 is approximately 14 microns.
  • the intermediate strata 21 b and 22 b have a density close to 450 g/m 2 .
  • each intermediate stratum 21 b and 22 b there is deposited on each intermediate stratum 21 b and 22 b an external stratum 21 c and 22 c of identical composition to the internal strata 21 a and 22 a.
  • the textile armature 1 is introduced by means of a conveyor belt 11 into a roller-type preliminary needle-puncher.
  • the density of the needles is 4.6 per square centimeter, the separation of the rollers is 20 mm, and the depth of penetration of the needles is 12 mm.
  • the belt moves at a speed of 10 meters per minute.
  • the textile armature 1 is passed through a hot-air tunnel oven 9 having a heating portion 20 meters long at a speed of 10 meters per minute.
  • the temperature of the hot-air tunnel oven 9 is approximately 120° C.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Inorganic Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
  • Reinforced Plastic Materials (AREA)
  • Moulding By Coating Moulds (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Woven Fabrics (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
US12/599,524 2007-05-15 2008-05-14 Reinforcement textile armature and method for making same Abandoned US20110151231A1 (en)

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Application Number Priority Date Filing Date Title
FR0755073A FR2916208B1 (fr) 2007-05-15 2007-05-15 Armature textile de renforcement et son procede de realisation.
FR0755073 2007-05-15
FR0757334A FR2916209B1 (fr) 2007-05-15 2007-09-03 Armature textile de renforcement et son procede de realisation
FR0757334 2007-09-03
PCT/IB2008/051905 WO2008139423A1 (fr) 2007-05-15 2008-05-14 Armature textile de renforcement et son procede de realisation

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US20120148790A1 (en) * 2009-08-21 2012-06-14 Gilbert Chomarat Reinforcement comprising parallel rovings of glass strands
CN109825946A (zh) * 2019-02-21 2019-05-31 浙江华恒复合材料有限公司 一种干法制备真空隔热板芯材的方法
US20190330429A1 (en) * 2012-10-02 2019-10-31 Claudio Cinquemani Method of making a semifinished product
WO2020186169A1 (en) * 2019-03-14 2020-09-17 Modern Meadow, Inc. Collagen-infused composite materials and methods of manufacturing the same
US11001679B2 (en) 2016-02-15 2021-05-11 Modern Meadow, Inc. Biofabricated material containing collagen fibrils
CN113186645A (zh) * 2021-04-28 2021-07-30 上海沥高科技股份有限公司 一种脱模透气毡及其制备方法和应用
US11214844B2 (en) 2017-11-13 2022-01-04 Modern Meadow, Inc. Biofabricated leather articles having zonal properties
US11352497B2 (en) 2019-01-17 2022-06-07 Modern Meadow, Inc. Layered collagen materials and methods of making the same
US11821120B2 (en) 2019-12-10 2023-11-21 Auria Solutions Uk I Ltd. Multi-layer needled nonwoven article and methods of manufacture thereof
US11913166B2 (en) 2015-09-21 2024-02-27 Modern Meadow, Inc. Fiber reinforced tissue composites

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FR2949238B1 (fr) * 2009-08-21 2011-09-09 Gilbert Chomarat Armature textile a fils de verre continus
FR2992000B1 (fr) 2012-06-18 2015-01-02 Chomarat Textiles Ind Procede de fabrication d'une armature textile de renforcement pour materiaux composites, et armature ainsi obtenue
FR3023565B1 (fr) * 2014-07-08 2016-07-08 Gilbert Chomarat Armature textile de renforcement et son procede de realisation
AU2019206704B2 (en) 2018-01-12 2024-02-08 Yeti Coolers, Llc Portable chair
USD904011S1 (en) 2019-01-14 2020-12-08 Yeti Coolers, Llc Bag
USD903305S1 (en) 2019-01-14 2020-12-01 Yeti Coolers, Llc Bag
USD902617S1 (en) 2019-01-14 2020-11-24 Yeti Coolers, Llc Portable chair
USD911731S1 (en) 2019-01-14 2021-03-02 Yeti Coolers, Llc Portable chair
USD912423S1 (en) 2019-01-14 2021-03-09 Yeti Coolers, Llc Portable chair

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Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20120148790A1 (en) * 2009-08-21 2012-06-14 Gilbert Chomarat Reinforcement comprising parallel rovings of glass strands
US20190330429A1 (en) * 2012-10-02 2019-10-31 Claudio Cinquemani Method of making a semifinished product
US10711109B2 (en) * 2012-10-02 2020-07-14 Reifenhauser Gmbh & Co. Kg Maschinenfabrik Method of making a semifinished product
US11913166B2 (en) 2015-09-21 2024-02-27 Modern Meadow, Inc. Fiber reinforced tissue composites
US11525042B2 (en) 2016-02-15 2022-12-13 Modern Meadow, Inc. Composite biofabricated material
US11542374B2 (en) 2016-02-15 2023-01-03 Modern Meadow, Inc. Composite biofabricated material
US11001679B2 (en) 2016-02-15 2021-05-11 Modern Meadow, Inc. Biofabricated material containing collagen fibrils
US11530304B2 (en) 2016-02-15 2022-12-20 Modern Meadow, Inc. Biofabricated material containing collagen fibrils
US11286354B2 (en) 2016-02-15 2022-03-29 Modern Meadow, Inc. Method for making a biofabricated material containing collagen fibrils
US11214844B2 (en) 2017-11-13 2022-01-04 Modern Meadow, Inc. Biofabricated leather articles having zonal properties
US11352497B2 (en) 2019-01-17 2022-06-07 Modern Meadow, Inc. Layered collagen materials and methods of making the same
CN109825946A (zh) * 2019-02-21 2019-05-31 浙江华恒复合材料有限公司 一种干法制备真空隔热板芯材的方法
WO2020186169A1 (en) * 2019-03-14 2020-09-17 Modern Meadow, Inc. Collagen-infused composite materials and methods of manufacturing the same
US11821120B2 (en) 2019-12-10 2023-11-21 Auria Solutions Uk I Ltd. Multi-layer needled nonwoven article and methods of manufacture thereof
CN113186645A (zh) * 2021-04-28 2021-07-30 上海沥高科技股份有限公司 一种脱模透气毡及其制备方法和应用

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CN101680144B (zh) 2013-01-23
EG25302A (en) 2011-12-07
IL202004A0 (en) 2010-06-16
NZ581626A (en) 2011-04-29
FR2916208B1 (fr) 2009-07-03
FR2916208A1 (fr) 2008-11-21
DE602008005441D1 (de) 2011-04-21
CA2687221A1 (fr) 2008-11-20
AU2008249626B2 (en) 2014-10-02
ATE501294T1 (de) 2011-03-15
KR20100024931A (ko) 2010-03-08
BRPI0811867A2 (pt) 2014-11-18
CA2687221C (fr) 2014-12-09
ZA200908582B (en) 2010-07-28
ES2362813T3 (es) 2011-07-13
AU2008249626A1 (en) 2008-11-20
FR2916209B1 (fr) 2009-07-03
DK2145036T3 (da) 2011-06-20
IL202004A (en) 2014-02-27
KR101518796B1 (ko) 2015-05-12
HRP20110358T1 (hr) 2011-08-31
JP5185370B2 (ja) 2013-04-17
JP2010526691A (ja) 2010-08-05
SI2145036T1 (sl) 2011-07-29
EP2145036A1 (fr) 2010-01-20
FR2916209A1 (fr) 2008-11-21
WO2008139423A1 (fr) 2008-11-20
PT2145036E (pt) 2011-06-15
HK1139441A1 (en) 2010-09-17
MX2009012354A (es) 2009-12-16
EP2145036B1 (fr) 2011-03-09
PL2145036T3 (pl) 2011-08-31
CN101680144A (zh) 2010-03-24
TN2009000473A1 (fr) 2011-03-31

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