US20150030804A1 - Sheetlike composite material - Google Patents
Sheetlike composite material Download PDFInfo
- Publication number
- US20150030804A1 US20150030804A1 US14/378,569 US201314378569A US2015030804A1 US 20150030804 A1 US20150030804 A1 US 20150030804A1 US 201314378569 A US201314378569 A US 201314378569A US 2015030804 A1 US2015030804 A1 US 2015030804A1
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- US
- United States
- Prior art keywords
- composite material
- layers
- layer
- fiber
- fibers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/14—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of indefinite length
- B29C39/20—Making multilayered or multicoloured articles
- B29C39/203—Making multilayered articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
- B29C43/30—Making multilayered or multicoloured articles
- B29C43/305—Making multilayered articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
- B29C51/145—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets having at least one layer of textile or fibrous material combined with at least one plastics layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
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- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C70/504—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands
- B29C70/506—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands and impregnating by melting a solid material, e.g. sheet, powder, fibres
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- 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
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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
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
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- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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- 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
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- 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
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- Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
- Y10T428/24074—Strand or strand-portions
- Y10T428/24091—Strand or strand-portions with additional layer[s]
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- 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
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Definitions
- the invention relates to a planar composite material containing two differently oriented unidirectional fiber-reinforced layers and at least one non-woven thermoplastic fiber layer or thermoplastic foil layer, stitched and needled to each other, and to a process for its production and to its use.
- Thermoplastics are increasingly used for producing molded parts, particularly components for automobiles, due to their low weight. To provide them with a sufficient strength and rigidity they are usually compounded with reinforcing fibers.
- planar semifinished products are produced from glass mat reinforced thermoplastics by means of merging endless glass fiber mats having randomly oriented fibers with thermoplastic molten sheets and consolidating on a double band press. From the planar semifinished product thus obtained, components can be produced by means of heat pressing in a mold.
- the fiber reinforcement is nondirectional, i.e., it acts equally in all directions with no preferred direction so that the strength of such composites is limited.
- components that are reinforced in preferred orientations are required.
- the fiber bundles are opened and the fibers are partially broken. In this process, however, the individual fibers are slightly displaced with respect to each other so that the orientation is partially removed and the reinforcing effect is reduced.
- the individual fiber bundles are connected, by means of binding threads, to each other and to the fibers of the nonwoven layer. In this process, however, the fiber bundles are not opened so that the thermoplastic melt can soak the woven or oriented fiber layer only incompletely, thus resulting in a lower loading capacity of the components produced therefrom.
- a further object of the invention is to provide planar composite materials which have a reinforcement in several directions, from which components with a bidirectional reinforcement can be produced.
- planar composite materials are described in EP 0 203 803 A1 and U.S. Pat. No. 3,761,345 A.
- EP 0 203 803 A1 relates to a reinforced resin mass which contains layers made of parallel reinforcing fibers and buffer layers made of aramide fibers. The fiber structure is embedded into a hardened resin.
- Aramide fibers are high performance reinforcement fibers made of an aromatic polyamide that in contrast to the aliphatic polyamides cannot be melted and, therefore, cannot be thermoplastically processed.
- U.S. Pat. No. 3,761,345 A describes a fiber complex that can absorb a resin. Glass fiber reinforced resin products can be produced therefrom by hardening of the resin.
- the fiber complex consists of a plurality of layers. Therein, the fibers can be present either unidirectionally or in the form of loops; furthermore, the central layer can also consist of tangled bundles of short chopped fibers. Fiber nonwoven layers in which the fibers consists at least partially of a thermoplastic are not disclosed in U.S. Pat. No. 3,761,345 A; moreover the production of components or semifinished products by means of thermoplastic heat pressing of the composite materials is not described.
- an object of the invention is a planar composite material, comprising
- the layers are both stitched to each other and also needled.
- thermoplastic as generally known in the technical field is to be understood in such manner that the corresponding materials can be melted and thermoplastically molded under conventional processing conditions.
- the fiber nonwoven of the layer A contains up to 50 wt.-% reinforcing fibers. According to another advantageous embodiment the fiber nonwoven of the layer A contains no reinforcing fibers and is, therefore, only made of thermoplastic fibers. According to a further advantageous embodiment the layer A is made of a thermoplastic foil.
- “Bidirectional” in the context with two oriented fiber layers B and B′ means that the longitudinal axis of the oriented fiber layer B is not parallel to the longitudinal axis of the oriented fiber layer B′.
- the fiber nonwoven-layer(s) A are produced according to the carding, airlay or spunbound nonwoven process or according to so-called paper making process, and subsequently the oriented fiber layers B and B′, which are bidirectionally aligned to each other, are continuously joined together with the layer(s) A.
- the layers are subsequently stitched to each other and thereafter needled.
- thermoplastic foil(s) of the layer A and the oriented fiber layers of the layers B and B′ which are bidirectionally aligned to each other, are continuously joined, stitched to each other and are thereafter needled.
- Preferred layer arrangements are B-A-B′ and B-A-B′-A-B. Further arrangements with a plurality of up to 20 layers are possible. It is preferred that always a fiber nonwoven or a thermoplastic foil layer A is arranged between two oriented layers B or B′. For specific applications, an arrangement in which one layer A is arranged at the outside is also possible.
- the fiber orientation of the layers B or B′ is bidirectional, and preferred orientations are 0°/90°, 30°/ ⁇ 30°, 45°/ ⁇ 45° and 60°/ ⁇ 60° with respect to a reference direction in the layer arrangement such as, for example, its longitudinal axis L. Accordingly, the acute angle between the respective fiber directions is preferably 60° or 90°. Thereby, the layers are preferably arranged symmetrically.
- FIG. 1 shows in a perspective view a layer arrangement B-A-B′ with a bidirectional fiber orientation 45°/ ⁇ 45° of the layers B and B′, respectively, with respect to a longitudinal axis L.
- the areal weights of the individual layers are preferably between 20 to 1,000 g/m 2 , particularly between 30 to 1,000 g/m 2 , more particularly between 150 and 300 g/m 2 .
- the individual oriented fiber layers may also have different areal weights.
- the areal weights are to be selected in such manner that the portion of the total reinforcing fibers in the composite material is preferably 20 to 80 wt.-%, more preferably 30 to 70 wt.-% and most preferably about 60 wt.-%.
- Preferred reinforcing fibers are glass fibers and carbon fibers; but also aramide fibers, basalt fibers, natural fibers, and fibers from higher melting polymers, as well as hybrid fibers, for example from glass fibers and polypropylene fibers, are suitable.
- the fiber types are in each case the same in the individual layers.
- the reinforcing fibers of the oriented fiber layer are preferably present as fiber bundle with a titer between 300 and 4,800 tex.
- thermoplastics in the fiber nonwoven or in the thermoplastic foil are polypropylene and meltable polyamides, particularly aliphatic polyamides; in addition, other thermoplastics such as polyester, polyether sulfone, polyether ketones and polyether imide are also suitable. Polyether ketones stand out particularly by a good heat resistance. Composite materials having a particularly good flowability can be obtained if the thermoplastic is polypropylene with a melt flow index (melt flow index, MFI) (230° C., 2.16 kg) between 10 and 400, particularly at about 120 g/10 min.
- MFI melt flow index
- the thermoplastics for producing the fiber nonwoven of the layer A can be provided in many different dimensions and geometries.
- the individual layers of the composite material are both stitched to each other and also needled.
- the fiber bundles of the oriented fiber layer are connected to each other by means of a stitching thread which forms meshes.
- a stitching thread which forms meshes.
- the reinforcing fibers are fixed in their parallel orientation.
- Suitable stitching threads can be made of glass, polypropylene, polyamide, and also of PET or polyether ketones. Acetate and viscose threads can also be used.
- the stitching threads are made of the same thermoplastic as the thermoplastic fibers or the thermoplastic foil of the layer A, that is, preferably also of polypropylene or polyamide.
- FIG. 2 show the layer arrangement B-A-B′ of FIG. 1 in a cross section along the fiber orientation of the layer B after stitching.
- the stitching thread N connects the fiber bundles of the layers B′ and B. Subsequently, this layer arrangement is also needled.
- thermoplastic fibers are drawn out of the nonwoven into the oriented fiber layer by the barbs of the needles.
- the needling can be carried out on conventional needling looms with felting needles.
- the number of needle stitches may vary between 5 and 100 per cm 2 , particularly between 20 and 40 punctures per cm 2 .
- thermoplastic melt penetrates from the fiber nonwoven or from the thermoplastic foil into the oriented fiber layers and can impregnate the same uniformly. If the stitching thread consists of the same thermoplast, it will also melt during the hot pressing; thereafter it is no longer needed.
- the fiber bundles are additionally stitched to each other, they keep their orientation upon needling, and because by the needling also the oriented fiber layer is connected to the fiber nonwoven layer or to the thermoplastic foil, there is also no risk for the layers to slip out of position during the transport and the subsequent processing.
- planar composite materials of the present invention can be directly pressed in molds to form three-dimensional components, or they can consolidated by means of heat pressing, for example, in a double band press, to planar semifinished products, preferably with a thickness of 0.5 to 5 mm.
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Abstract
A sheetlike composite material including at least one layer A of a nonwoven thermoplastic fibre web or a thermoplastic film, and at least two unidirectional oriented-fibre layers B and B′, the layers B and B′ having a bidirectional fibre orientation. The layers are not only needled but also stitched to one another.
Description
- This application is the U.S. National Phase of PCT/EP2013/052616 filed Feb. 8, 2013, which claims priority to European Patent Application No. 12154516.4 filed Feb. 8, 2012, the disclosures of which are incorporated in their entirety by reference herein.
- 1. Field of the Invention
- The invention relates to a planar composite material containing two differently oriented unidirectional fiber-reinforced layers and at least one non-woven thermoplastic fiber layer or thermoplastic foil layer, stitched and needled to each other, and to a process for its production and to its use.
- 2. Description of the Related Art
- Thermoplastics are increasingly used for producing molded parts, particularly components for automobiles, due to their low weight. To provide them with a sufficient strength and rigidity they are usually compounded with reinforcing fibers. For example, planar semifinished products are produced from glass mat reinforced thermoplastics by means of merging endless glass fiber mats having randomly oriented fibers with thermoplastic molten sheets and consolidating on a double band press. From the planar semifinished product thus obtained, components can be produced by means of heat pressing in a mold. However, in this process the fiber reinforcement is nondirectional, i.e., it acts equally in all directions with no preferred direction so that the strength of such composites is limited. However, in many cases components that are reinforced in preferred orientations are required. This can be achieved by using fiber woven or oriented fiber layers made of parallel fiber bundles (rovings) as reinforcing fibers. For example, in WO 2006/111037, there is described a planar composite material which contains a fiber nonwoven-layer made of thermoplastic fibers and a woven or oriented layer made of parallel reinforcing fiber bundles. The individual layers can be either needled together or thermally bonded to each other. This composite material can be processed by means of heat pressing to form components having controlled reinforcement.
- Upon needling, the fiber bundles are opened and the fibers are partially broken. In this process, however, the individual fibers are slightly displaced with respect to each other so that the orientation is partially removed and the reinforcing effect is reduced. Upon stitching, the individual fiber bundles are connected, by means of binding threads, to each other and to the fibers of the nonwoven layer. In this process, however, the fiber bundles are not opened so that the thermoplastic melt can soak the woven or oriented fiber layer only incompletely, thus resulting in a lower loading capacity of the components produced therefrom.
- Therefore, it was an object of the invention to provide composite materials reinforced with oriented fiber layers which do not have the respective disadvantages mentioned. A further object of the invention is to provide planar composite materials which have a reinforcement in several directions, from which components with a bidirectional reinforcement can be produced.
- In principle, the latter is also achieved with the composite materials according to WO 2006/111307 if a fiber woven fabric is used for reinforcing. However, in woven fabrics the fiber bundles are undulated at the crossing points, thus resulting in a reduction of the compressive strength in the fiber direction. Moreover, there is no thermoplastic at the crossing points between the fiber bundles. These dry spots result in an irregular impregnation. Also these disadvantages should be avoided by the present invention.
- Other types of planar composite materials are described in EP 0 203 803 A1 and U.S. Pat. No. 3,761,345 A.
- EP 0 203 803 A1 relates to a reinforced resin mass which contains layers made of parallel reinforcing fibers and buffer layers made of aramide fibers. The fiber structure is embedded into a hardened resin. Aramide fibers are high performance reinforcement fibers made of an aromatic polyamide that in contrast to the aliphatic polyamides cannot be melted and, therefore, cannot be thermoplastically processed.
- U.S. Pat. No. 3,761,345 A describes a fiber complex that can absorb a resin. Glass fiber reinforced resin products can be produced therefrom by hardening of the resin. The fiber complex consists of a plurality of layers. Therein, the fibers can be present either unidirectionally or in the form of loops; furthermore, the central layer can also consist of tangled bundles of short chopped fibers. Fiber nonwoven layers in which the fibers consists at least partially of a thermoplastic are not disclosed in U.S. Pat. No. 3,761,345 A; moreover the production of components or semifinished products by means of thermoplastic heat pressing of the composite materials is not described.
- Therefore, an object of the invention is a planar composite material, comprising
-
- at least one layer A made of a fiber nonwoven consisting of 40 to 100 wt.-% thermoplastic fibers and 60 to 0 wt.-% reinforcing fibers, or of a thermoplastic foil, and
- at least two unidirectionally oriented fiber layers B and B′ made of parallel reinforcing fiber bundles, wherein the layers B and B′ have a bidirectional fiber orientation.
- According to the present invention, in the composite material the layers are both stitched to each other and also needled.
- The term “thermoplastic” as generally known in the technical field is to be understood in such manner that the corresponding materials can be melted and thermoplastically molded under conventional processing conditions.
- According to an advantageous embodiment the fiber nonwoven of the layer A contains up to 50 wt.-% reinforcing fibers. According to another advantageous embodiment the fiber nonwoven of the layer A contains no reinforcing fibers and is, therefore, only made of thermoplastic fibers. According to a further advantageous embodiment the layer A is made of a thermoplastic foil.
- “Bidirectional” in the context with two oriented fiber layers B and B′ means that the longitudinal axis of the oriented fiber layer B is not parallel to the longitudinal axis of the oriented fiber layer B′.
- Further objects of the invention are processes for producing such composite materials. There are two variants therefor:
- In the first variant, initially the fiber nonwoven-layer(s) A are produced according to the carding, airlay or spunbound nonwoven process or according to so-called paper making process, and subsequently the oriented fiber layers B and B′, which are bidirectionally aligned to each other, are continuously joined together with the layer(s) A. The layers are subsequently stitched to each other and thereafter needled.
- In the second variant, the thermoplastic foil(s) of the layer A and the oriented fiber layers of the layers B and B′, which are bidirectionally aligned to each other, are continuously joined, stitched to each other and are thereafter needled.
- Preferred layer arrangements are B-A-B′ and B-A-B′-A-B. Further arrangements with a plurality of up to 20 layers are possible. It is preferred that always a fiber nonwoven or a thermoplastic foil layer A is arranged between two oriented layers B or B′. For specific applications, an arrangement in which one layer A is arranged at the outside is also possible.
- The fiber orientation of the layers B or B′ is bidirectional, and preferred orientations are 0°/90°, 30°/−30°, 45°/−45° and 60°/−60° with respect to a reference direction in the layer arrangement such as, for example, its longitudinal axis L. Accordingly, the acute angle between the respective fiber directions is preferably 60° or 90°. Thereby, the layers are preferably arranged symmetrically.
-
FIG. 1 shows in a perspective view a layer arrangement B-A-B′ with a bidirectional fiber orientation 45°/−45° of the layers B and B′, respectively, with respect to a longitudinal axis L. - The areal weights of the individual layers are preferably between 20 to 1,000 g/m2, particularly between 30 to 1,000 g/m2, more particularly between 150 and 300 g/m2. The individual oriented fiber layers may also have different areal weights. The areal weights are to be selected in such manner that the portion of the total reinforcing fibers in the composite material is preferably 20 to 80 wt.-%, more preferably 30 to 70 wt.-% and most preferably about 60 wt.-%.
- Preferred reinforcing fibers are glass fibers and carbon fibers; but also aramide fibers, basalt fibers, natural fibers, and fibers from higher melting polymers, as well as hybrid fibers, for example from glass fibers and polypropylene fibers, are suitable. Preferably, the fiber types are in each case the same in the individual layers. The reinforcing fibers of the oriented fiber layer are preferably present as fiber bundle with a titer between 300 and 4,800 tex.
- Preferred thermoplastics in the fiber nonwoven or in the thermoplastic foil are polypropylene and meltable polyamides, particularly aliphatic polyamides; in addition, other thermoplastics such as polyester, polyether sulfone, polyether ketones and polyether imide are also suitable. Polyether ketones stand out particularly by a good heat resistance. Composite materials having a particularly good flowability can be obtained if the thermoplastic is polypropylene with a melt flow index (melt flow index, MFI) (230° C., 2.16 kg) between 10 and 400, particularly at about 120 g/10 min. The thermoplastics for producing the fiber nonwoven of the layer A can be provided in many different dimensions and geometries.
- The individual layers of the composite material are both stitched to each other and also needled.
- Upon stitching, the fiber bundles of the oriented fiber layer are connected to each other by means of a stitching thread which forms meshes. Thereby, the reinforcing fibers are fixed in their parallel orientation. Suitable stitching threads can be made of glass, polypropylene, polyamide, and also of PET or polyether ketones. Acetate and viscose threads can also be used.
- Preferably, the stitching threads are made of the same thermoplastic as the thermoplastic fibers or the thermoplastic foil of the layer A, that is, preferably also of polypropylene or polyamide.
-
FIG. 2 show the layer arrangement B-A-B′ ofFIG. 1 in a cross section along the fiber orientation of the layer B after stitching. Thereby, the stitching thread N connects the fiber bundles of the layers B′ and B. Subsequently, this layer arrangement is also needled. - Upon needling, as already explained, the fiber bundles are opened and the fibers are partially broken. Moreover, thermoplastic fibers are drawn out of the nonwoven into the oriented fiber layer by the barbs of the needles. The same happens also upon needling the thermoplastic foil, where fragments or threads are torn out of the foil and drawn into the oriented fiber layer by the barbs. The needling can be carried out on conventional needling looms with felting needles. The number of needle stitches may vary between 5 and 100 per cm2, particularly between 20 and 40 punctures per cm2.
- All this has the result that by the subsequent hot pressing the thermoplastic melt penetrates from the fiber nonwoven or from the thermoplastic foil into the oriented fiber layers and can impregnate the same uniformly. If the stitching thread consists of the same thermoplast, it will also melt during the hot pressing; thereafter it is no longer needed.
- Due to the fact that the fiber bundles are additionally stitched to each other, they keep their orientation upon needling, and because by the needling also the oriented fiber layer is connected to the fiber nonwoven layer or to the thermoplastic foil, there is also no risk for the layers to slip out of position during the transport and the subsequent processing.
- At temperatures above the softening range of the thermoplastic the planar composite materials of the present invention can be directly pressed in molds to form three-dimensional components, or they can consolidated by means of heat pressing, for example, in a double band press, to planar semifinished products, preferably with a thickness of 0.5 to 5 mm.
Claims (19)
1.-15. (canceled)
16. A planar composite material comprising
a) at least one layer A made of a fiber nonwoven consisting of 40 to 100 wt.-% thermoplastic fibers and 60 to 0 wt.-% reinforcing fibers, or of a thermoplastic foil, and
b) at least two unidirectionally oriented fiber layers B and B′ comprising parallel reinforcing fiber bundles, wherein at least two layers B and B′ have a bidirectional fiber orientation,
wherein the layers are both stitched to each other and also needled.
17. The composite material of claim 16 , wherein a layer arrangement is B-A-B′ or B-A-B′-A-B.
18. The composite material of claim 16 , wherein the fiber orientation of the layers B and B′ with respect to a reference direction of the composite material is 0°/90°, 30°/−30°, 45°/−45° or 60°/−60°.
19. The composite material of claim 16 , the areal weights of the individual layers each are 20 to 1,000 g/m2.
20. The composite material of claim 16 , the areal weights of the individual layers each are 30 to 1,000 g/m2.
21. The composite material of claim 16 , the areal weights of the individual layers each are 150 to 3,000 g/m2.
22. The composite material of claim 16 , wherein the total amount of reinforcing fibers in the composite material is 20 to 80 wt.-%, based on the total weight of the composite material.
23. The composite material of claim 16 , wherein the reinforcing fibers comprise glass fibers or carbon fibers.
24. The composite material of claim 16 , wherein the thermoplastic fibers or the thermoplastic foil of the layer A comprise polypropylene.
25. The composite material of claim 24 , wherein threads used for stitching comprise polypropylene.
26. The composite material of claim 16 , wherein the thermoplastic fibers or the thermoplastic foil of the layer A comprise polyamide.
27. The composite material of claim 26 , wherein the threads used for stitching comprise polyamide.
28. The composite material of claim 16 , wherein the thermoplastic fibers or the thermoplastic foil of the layer A comprise polyether ketone.
29. The composite material of claim 28 , the threads used for stitching comprise polyether ketone.
30. A method for producing a composite material of claim 16 , comprising:
a) fiber nonwoven layer(s) A produced by a carding, airlay or spunbound nonwoven process are provided, and oriented fiber layers B and B′ are continuously merged together with the fiber nonwoven layer(s) A, and subsequently the layers are stitched to each other and thereafter needled; or
b) thermoplastic foil(s) of the layer(s) A and the oriented fiber layers B and B′ are continuously merged together, the layers are stitched to each other, and thereafter needled.
31. A process for producing three-dimensional components comprising heat pressing a composite material of claim 16 in a mold.
32. A process for producing a planar semifinished product with a thickness of 0.5 to 5 mm comprising of heat pressing a composite material of claim 16 in a double band press.
33. A planar heat-moldable semi-finished product comprising a molding having a thickness of 0.5 to 5 mm prepared by thermally consolidating a composite material of claim 16 in a double band press.
Applications Claiming Priority (3)
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EP12154516.4A EP2626200A1 (en) | 2012-02-08 | 2012-02-08 | Flat compound material |
PCT/EP2013/052616 WO2013117743A1 (en) | 2012-02-08 | 2013-02-08 | Sheetlike composite material |
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US16/849,535 Pending US20200238659A1 (en) | 2012-02-08 | 2020-04-15 | Planar composite material |
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- 2012-02-08 EP EP12154516.4A patent/EP2626200A1/en not_active Ceased
-
2013
- 2013-02-08 US US14/378,569 patent/US20150030804A1/en not_active Abandoned
- 2013-02-08 EP EP13707292.2A patent/EP2812184A1/en not_active Withdrawn
- 2013-02-08 CN CN201380014808.9A patent/CN104169077B/en not_active Expired - Fee Related
- 2013-02-08 WO PCT/EP2013/052616 patent/WO2013117743A1/en active Application Filing
-
2017
- 2017-09-12 US US15/702,146 patent/US20180001594A1/en not_active Abandoned
-
2020
- 2020-04-15 US US16/849,535 patent/US20200238659A1/en active Pending
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Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11987011B2 (en) * | 2016-11-30 | 2024-05-21 | Teijin Automotive Technologies, Inc. | Hybrid fiber based molding thermoplastic article and process of forming same |
US11633939B2 (en) * | 2017-04-03 | 2023-04-25 | Quadrant Plastic Composites, AG | Method for producing a planar composite component and composite component produced thereby |
US20230286224A1 (en) * | 2017-10-06 | 2023-09-14 | Mitsubishi Chemical Advanced Materials Composites Ag | Method of manufacturing a composite part comprising a core and at least one skin region |
US11664546B2 (en) | 2017-12-21 | 2023-05-30 | H.K.O. Isolier—Und Textiltechnik Gmbh | Multi-layer thermal insulation element for batteries |
US12095066B2 (en) | 2017-12-21 | 2024-09-17 | H.K.O. Isolier—Und Textiltechnik Gmbh | Multi-layer thermal insulation element for batteries |
US20190390379A1 (en) * | 2018-06-26 | 2019-12-26 | GM Global Technology Operations LLC | Methods for forming composite articles from non-crimp fabrics |
US11111610B2 (en) * | 2018-06-26 | 2021-09-07 | GM Global Technology Operations LLC | Methods for forming composite articles from non-crimp fabrics |
US11753754B2 (en) | 2018-08-21 | 2023-09-12 | Owens Corning Intellectual Capital, Llc | Multiaxial reinforcing fabric with a stitching yarn for improved fabric infusion |
US11913148B2 (en) | 2018-08-21 | 2024-02-27 | Owens Corning Intellectual Capital, Llc | Hybrid reinforcement fabric |
Also Published As
Publication number | Publication date |
---|---|
EP2626200A1 (en) | 2013-08-14 |
US20200238659A1 (en) | 2020-07-30 |
WO2013117743A1 (en) | 2013-08-15 |
US20180001594A1 (en) | 2018-01-04 |
CN104169077B (en) | 2017-02-22 |
EP2812184A1 (en) | 2014-12-17 |
CN104169077A (en) | 2014-11-26 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: QUADRANT PLASTIC COMPOSITES AG, SWITZERLAND Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:BASER, BURAK;REEL/FRAME:034100/0012 Effective date: 20140828 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |