US20150375464A1 - Method for producing a multilayer composite material, multilayer composite material obtained by the method and mechanical parts or structures produced with said material - Google Patents
Method for producing a multilayer composite material, multilayer composite material obtained by the method and mechanical parts or structures produced with said material Download PDFInfo
- Publication number
- US20150375464A1 US20150375464A1 US14/772,101 US201414772101A US2015375464A1 US 20150375464 A1 US20150375464 A1 US 20150375464A1 US 201414772101 A US201414772101 A US 201414772101A US 2015375464 A1 US2015375464 A1 US 2015375464A1
- Authority
- US
- United States
- Prior art keywords
- composite material
- multilayer composite
- meth
- thermoplastic
- acrylic
- 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
Links
- 239000011185 multilayer composite material Substances 0.000 title claims abstract description 59
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 54
- 238000000034 method Methods 0.000 title claims abstract description 52
- 239000000463 material Substances 0.000 title abstract description 17
- 229920001169 thermoplastic Polymers 0.000 claims abstract description 95
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims abstract description 65
- 239000010410 layer Substances 0.000 claims abstract description 54
- 239000006188 syrup Substances 0.000 claims abstract description 43
- 235000020357 syrup Nutrition 0.000 claims abstract description 43
- 239000002657 fibrous material Substances 0.000 claims abstract description 39
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract description 39
- 239000000758 substrate Substances 0.000 claims abstract description 37
- 239000002344 surface layer Substances 0.000 claims abstract description 36
- 239000007788 liquid Substances 0.000 claims abstract description 34
- 229920000058 polyacrylate Polymers 0.000 claims abstract description 27
- 239000011159 matrix material Substances 0.000 claims abstract description 25
- 238000005520 cutting process Methods 0.000 claims abstract description 12
- 229920006352 transparent thermoplastic Polymers 0.000 claims abstract description 10
- 230000000379 polymerizing effect Effects 0.000 claims abstract description 5
- 239000002131 composite material Substances 0.000 claims description 51
- 239000000835 fiber Substances 0.000 claims description 47
- 239000000178 monomer Substances 0.000 claims description 34
- 239000000203 mixture Substances 0.000 claims description 31
- 229920001577 copolymer Polymers 0.000 claims description 28
- 229920000642 polymer Polymers 0.000 claims description 26
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 claims description 22
- 239000012815 thermoplastic material Substances 0.000 claims description 17
- -1 polypropylene Polymers 0.000 claims description 15
- 229920002877 acrylic styrene acrylonitrile Polymers 0.000 claims description 13
- 239000002033 PVDF binder Substances 0.000 claims description 12
- 229920002981 polyvinylidene fluoride Polymers 0.000 claims description 12
- 230000003014 reinforcing effect Effects 0.000 claims description 11
- 239000004698 Polyethylene Substances 0.000 claims description 9
- 238000005470 impregnation Methods 0.000 claims description 9
- 229920000573 polyethylene Polymers 0.000 claims description 9
- 238000006116 polymerization reaction Methods 0.000 claims description 9
- 239000004801 Chlorinated PVC Substances 0.000 claims description 8
- 239000004743 Polypropylene Substances 0.000 claims description 8
- 229920002492 poly(sulfone) Polymers 0.000 claims description 8
- 239000004417 polycarbonate Substances 0.000 claims description 8
- 229920000515 polycarbonate Polymers 0.000 claims description 8
- 229920006380 polyphenylene oxide Polymers 0.000 claims description 8
- 229920001155 polypropylene Polymers 0.000 claims description 8
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 claims description 7
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 7
- YAAQEISEHDUIFO-UHFFFAOYSA-N C=CC#N.OC(=O)C=CC=CC1=CC=CC=C1 Chemical compound C=CC#N.OC(=O)C=CC=CC1=CC=CC=C1 YAAQEISEHDUIFO-UHFFFAOYSA-N 0.000 claims description 6
- 239000004793 Polystyrene Substances 0.000 claims description 6
- 229920006397 acrylic thermoplastic Polymers 0.000 claims description 6
- 229920001519 homopolymer Polymers 0.000 claims description 6
- 229920002223 polystyrene Polymers 0.000 claims description 6
- 239000011347 resin Substances 0.000 claims description 6
- 229920005989 resin Polymers 0.000 claims description 6
- 238000001721 transfer moulding Methods 0.000 claims description 6
- 230000005540 biological transmission Effects 0.000 claims description 5
- 239000002557 mineral fiber Substances 0.000 claims description 5
- 229920000728 polyester Polymers 0.000 claims description 5
- 239000004814 polyurethane Substances 0.000 claims description 5
- 239000004800 polyvinyl chloride Substances 0.000 claims description 5
- 238000003856 thermoforming Methods 0.000 claims description 5
- 241001465754 Metazoa Species 0.000 claims description 4
- 229920006395 saturated elastomer Polymers 0.000 claims description 4
- 239000011145 styrene acrylonitrile resin Substances 0.000 claims description 4
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 3
- 229920002522 Wood fibre Polymers 0.000 claims description 3
- 239000004917 carbon fiber Substances 0.000 claims description 3
- 239000003365 glass fiber Substances 0.000 claims description 3
- 238000001802 infusion Methods 0.000 claims description 3
- 239000003999 initiator Substances 0.000 claims description 3
- 239000002025 wood fiber Substances 0.000 claims description 3
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 claims description 2
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 claims description 2
- 238000010276 construction Methods 0.000 claims description 2
- 238000010030 laminating Methods 0.000 claims description 2
- 238000003475 lamination Methods 0.000 claims description 2
- 239000012779 reinforcing material Substances 0.000 abstract description 3
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 11
- 239000004926 polymethyl methacrylate Substances 0.000 description 11
- 229920001187 thermosetting polymer Polymers 0.000 description 9
- BAPJBEWLBFYGME-UHFFFAOYSA-N Methyl acrylate Chemical compound COC(=O)C=C BAPJBEWLBFYGME-UHFFFAOYSA-N 0.000 description 6
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 5
- 239000000654 additive Substances 0.000 description 5
- 125000000217 alkyl group Chemical group 0.000 description 5
- 239000011248 coating agent Substances 0.000 description 5
- 238000000576 coating method Methods 0.000 description 5
- 239000005020 polyethylene terephthalate Substances 0.000 description 5
- 239000004634 thermosetting polymer Substances 0.000 description 5
- PSGCQDPCAWOCSH-UHFFFAOYSA-N (4,7,7-trimethyl-3-bicyclo[2.2.1]heptanyl) prop-2-enoate Chemical compound C1CC2(C)C(OC(=O)C=C)CC1C2(C)C PSGCQDPCAWOCSH-UHFFFAOYSA-N 0.000 description 3
- 241000196324 Embryophyta Species 0.000 description 3
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 3
- 238000004132 cross linking Methods 0.000 description 3
- 239000004744 fabric Substances 0.000 description 3
- 229920006305 unsaturated polyester Polymers 0.000 description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 2
- SOGAXMICEFXMKE-UHFFFAOYSA-N Butylmethacrylate Chemical compound CCCCOC(=O)C(C)=C SOGAXMICEFXMKE-UHFFFAOYSA-N 0.000 description 2
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 description 2
- 239000004609 Impact Modifier Substances 0.000 description 2
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 229920001400 block copolymer Polymers 0.000 description 2
- 125000004432 carbon atom Chemical group C* 0.000 description 2
- 239000000470 constituent Substances 0.000 description 2
- 125000004122 cyclic group Chemical group 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 238000005227 gel permeation chromatography Methods 0.000 description 2
- 239000012760 heat stabilizer Substances 0.000 description 2
- 229940063557 methacrylate Drugs 0.000 description 2
- 125000005395 methacrylic acid group Chemical group 0.000 description 2
- 239000004745 nonwoven fabric Substances 0.000 description 2
- 239000006259 organic additive Substances 0.000 description 2
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 238000004064 recycling Methods 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 229920001567 vinyl ester resin Polymers 0.000 description 2
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 2
- RUMACXVDVNRZJZ-UHFFFAOYSA-N 2-methylpropyl 2-methylprop-2-enoate Chemical compound CC(C)COC(=O)C(C)=C RUMACXVDVNRZJZ-UHFFFAOYSA-N 0.000 description 1
- CFVWNXQPGQOHRJ-UHFFFAOYSA-N 2-methylpropyl prop-2-enoate Chemical compound CC(C)COC(=O)C=C CFVWNXQPGQOHRJ-UHFFFAOYSA-N 0.000 description 1
- 229920006942 ABS/PC Polymers 0.000 description 1
- 244000198134 Agave sisalana Species 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 244000025254 Cannabis sativa Species 0.000 description 1
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 description 1
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 description 1
- 244000060011 Cocos nucifera Species 0.000 description 1
- 235000013162 Cocos nucifera Nutrition 0.000 description 1
- 240000000491 Corchorus aestuans Species 0.000 description 1
- 235000011777 Corchorus aestuans Nutrition 0.000 description 1
- 235000010862 Corchorus capsularis Nutrition 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 241000219146 Gossypium Species 0.000 description 1
- 240000006240 Linum usitatissimum Species 0.000 description 1
- 235000004431 Linum usitatissimum Nutrition 0.000 description 1
- 240000008790 Musa x paradisiaca Species 0.000 description 1
- 235000018290 Musa x paradisiaca Nutrition 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 239000012963 UV stabilizer Substances 0.000 description 1
- IAXXETNIOYFMLW-COPLHBTASA-N [(1s,3s,4s)-4,7,7-trimethyl-3-bicyclo[2.2.1]heptanyl] 2-methylprop-2-enoate Chemical compound C1C[C@]2(C)[C@@H](OC(=O)C(=C)C)C[C@H]1C2(C)C IAXXETNIOYFMLW-COPLHBTASA-N 0.000 description 1
- 150000001252 acrylic acid derivatives Chemical class 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 125000005250 alkyl acrylate group Chemical group 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 description 1
- 125000000484 butyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 235000009120 camo Nutrition 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 235000005607 chanvre indien Nutrition 0.000 description 1
- 239000008199 coating composition Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229920006037 cross link polymer Polymers 0.000 description 1
- OIWOHHBRDFKZNC-UHFFFAOYSA-N cyclohexyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OC1CCCCC1 OIWOHHBRDFKZNC-UHFFFAOYSA-N 0.000 description 1
- KBLWLMPSVYBVDK-UHFFFAOYSA-N cyclohexyl prop-2-enoate Chemical compound C=CC(=O)OC1CCCCC1 KBLWLMPSVYBVDK-UHFFFAOYSA-N 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- SUPCQIBBMFXVTL-UHFFFAOYSA-N ethyl 2-methylprop-2-enoate Chemical compound CCOC(=O)C(C)=C SUPCQIBBMFXVTL-UHFFFAOYSA-N 0.000 description 1
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 1
- 238000002270 exclusion chromatography Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 210000004209 hair Anatomy 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000011487 hemp Substances 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 229940091853 isobornyl acrylate Drugs 0.000 description 1
- 229940119545 isobornyl methacrylate Drugs 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 150000002734 metacrylic acid derivatives Chemical class 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000005445 natural material Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920006254 polymer film Polymers 0.000 description 1
- 239000002952 polymeric resin Substances 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000012783 reinforcing fiber Substances 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 239000012780 transparent material Substances 0.000 description 1
- 238000009755 vacuum infusion Methods 0.000 description 1
- 238000001429 visible spectrum Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
- 210000002268 wool Anatomy 0.000 description 1
Images
Classifications
-
- 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
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/545—Perforating, cutting or machining during or after moulding
-
- 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
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
- B29C70/745—Filling cavities in the preformed part
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
-
- 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
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
- B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
-
- 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
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
-
- 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
-
- 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
- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
- B29K2023/04—Polymers of ethylene
-
- 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
- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
- B29K2023/10—Polymers of propylene
-
- 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
- B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
- B29K2025/04—Polymers of styrene
- B29K2025/06—PS, i.e. polystyrene
-
- 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
- B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
- B29K2033/04—Polymers of esters
-
- 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
- B29K2055/00—Use of specific polymers obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in a single one of main groups B29K2023/00 - B29K2049/00, e.g. having a vinyl group, as moulding material
- B29K2055/02—ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
-
- 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
- B29K2081/00—Use of polymers having sulfur, with or without nitrogen, oxygen or carbon only, in the main chain, as moulding material
- B29K2081/06—PSU, i.e. polysulfones; PES, i.e. polyethersulfones or derivatives thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2009/00—Layered products
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/778—Windows
- B29L2031/7782—Glazing
-
- 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
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/021—Fibrous or filamentary 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
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/412—Transparent
-
- 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
- B32B2419/00—Buildings or parts thereof
-
- 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
- B32B2451/00—Decorative or ornamental articles
-
- 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
- B32B2457/00—Electrical equipment
-
- 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
- B32B2457/00—Electrical equipment
- B32B2457/12—Photovoltaic modules
-
- 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
- B32B2603/00—Vanes, blades, propellers, rotors with blades
-
- 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
- B32B2605/00—Vehicles
-
- 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
- B32B2605/00—Vehicles
- B32B2605/12—Ships
-
- 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
- B32B2605/00—Vehicles
- B32B2605/18—Aircraft
Definitions
- the present invention relates to a process for manufacturing a multilayer composite material comprising a surface layer comprising a thermoplastic polymer A, a substrate layer comprising a polymeric composite material based on a thermoplastic (meth)acrylic polymer matrix and a reinforcing fibrous material, and which allows the formation of one or more windows comprising a thermoplastic material, which may be transparent.
- the process is particularly suited to the production of parts or elements of two-dimensional or three-dimensional mechanical structures or of decorative articles requiring one or more windows comprising a thermoplastic material, which may be transparent.
- a subject of the invention is also a multilayer composite material comprising one or more windows made of thermoplastic material which may be transparent, obtained via the process and parts or elements of two-dimensional or three-dimensional mechanical structures or of decorative articles made with said material.
- a composite material is a macroscopic combination of two or more non-miscible materials.
- the composite material consists of at least one material which forms the matrix, i.e. a continuous phase that ensures the cohesion of the structure, and a reinforcing material.
- composite materials are widely used in several industrial sectors, for instance building, automotive, aerospace, transport, leisure, electronics, and sport notably due to their better mechanical performance (higher tensile strength, higher tensile modulus, higher fracture toughness) in comparison with homogeneous materials, and their low density.
- the most important class in view of volume at the commercial industrial scale, is that of composites with organic matrices, in which the matrix material is generally a polymer.
- the main matrix or continuous phase of a polymeric composite material is either a thermoplastic polymer or a thermosetting polymer.
- Thermosetting polymers consist of crosslinked three-dimensional structures.
- the crosslinking is obtained by curing reactive groups in said prepolymer. Curing may be obtained, for example, by heating the polymer chains in order to crosslink and harden the material permanently.
- the prepolymer is mixed with the other component such as glass beads or fibers, or the other component is wetted or impregnated and cured afterwards.
- the other component such as glass beads or fibers
- prepolymers or matrix materials for thermosetting polymers are unsaturated polyesters, vinyl esters, and epoxy or phenolic materials.
- thermosetting polymeric matrix A major drawback of a thermosetting polymeric matrix is its crosslinking.
- the matrix cannot be easily fashioned into other forms. Once the polymer has crosslinked, the form is set. This also makes the recycling of thermosetting composite material difficult, and manufactured mechanical or structured parts or articles comprising said thermosetting composite material are burned in a cement plant or thrown into a waste dump.
- thermoplastic polymers To allow thermoforming and recycling, it is preferred to use thermoplastic polymers.
- Thermoplastic polymers consist of linear or branched polymers, which are not crosslinked.
- the thermoplastic polymers are heated in order to mix the constituents required for manufacturing the composite material and are cooled to set the final form.
- the problem of these molten thermoplastic polymers is their very high viscosity.
- thermoplastic polymer resin in the molten state commonly known as a “syrup” is used to impregnate the reinforcing material, for example a fibrous substrate.
- the thermoplastic polymeric syrup constitutes the matrix of the composite material.
- the viscosity of the impregnation syrup must be controlled and adapted so as not to be too fluid or too viscous, so as to correctly impregnate each fiber of the fibrous substrate and to avoid the appearance of defects in the final composite material, which give rise, inter alia, to a loss of mechanical strength of the final composite material.
- an additional surface layer is applied. This may be performed by means of a “gel coat” surface coat or a coat of paint.
- the gel coat is usually produced chemically by an epoxy resin or an unsaturated polyester, treated to form a crosslinked polymer which adheres to the composite material.
- the multilayer material comprising a thermoplastic composite loses the properties of thermoplastic polymers and can no longer be thermoformed or recycled.
- the multilayer composite material for producing mechanical parts or structured elements or articles comprises:
- the Applicant is confronted with another technical problem, namely the production of transparent or non-transparent windows in multilayer composite materials.
- This need is particularly experienced in the production of mechanical parts or structured elements or articles that require a visibility zone in the sense that it can be seen through, for instance a motor vehicle windshield, a visibility screen in an appliance shell (for instance recharging terminals, roadside emergency terminals, etc.), a boat hull including portholes, a car sunroof or alternatively for decorative objects.
- the aim of the present invention is to solve this technical problem.
- the invention is directed toward proposing a process for producing a multilayer composite material which can be performed at low cost, which includes the production of one or more windows made of transparent or non-transparent material and which allows manufacture at the industrial scale, for producing structural parts made of a thermoplastic multilayer composite material comprising at least one transparent or non-transparent window.
- the process should be quick and simple to perform using commercially available components.
- the manufacture of the parts should also be reproducible and fast, meaning short cycle times.
- Another object of the present invention is to be able to manufacture a composite multilayer structure for producing parts comprising a thermoplastic composite material with one or more transparent or non-transparent windows, having a surface appearance that satisfactorily hides the fibrous appearance of the surface layer while at the same time remaining a thermoplastic composite material.
- Another object of the present invention is to be able to manufacture multilayer structural parts comprising a thermoplastic composite material with one or more transparent or non-transparent windows, in which the adhesion between the various respective layers does not require any additional adhesive materials.
- Another aim of the present invention is to be able to manufacture multilayer structural parts comprising a thermoplastic composite material with transparent or non-transparent windows, which can be transformed and fashioned by virtue of the flexibility of each layer.
- Another object of the invention is to be able to recycle structural parts comprising a multilayer material which are worn out or which do not meet the manufacturing quality criteria.
- Document WO 2012/136235 describes a process for producing a bodywork multi-fiber composite material with a class A surface coating.
- the surface is obtained by applying a spray via a mold coating system and processing.
- the coating is not thermoplastic and, consequently, it cannot be thermoformed or recycled.
- Patent WO 2007/021797 describes a powdered coating composition for coating the surface of thermoplastic composites.
- the powdered coating comprises a vinyl acetate copolymer and a thermoplastic or thermosetting binder.
- thermoplastic multilayer composite material comprising one or more windows, which make it possible to solve the technical problems mentioned above.
- No document describes a process for manufacturing such a material.
- the windows are produced via the same process for manufacturing the multilayer composite material.
- the production of one or more windows is included in the steps for manufacturing the multilayer composite material.
- the material present in the windows is obtained by inserting a thermoplastic plate into said windows and/or with the impregnation and polymerization steps for manufacturing the multilayer composite material, which represents a saving in time and simplification for the manufacture of parts at the industrial scale.
- thermoplastic plate into the window(s) in the process for manufacturing the multilayer composite material makes it possible, by means of the impregnation and polymerization steps, to integrally attach/seal the plate(s) to the layers constituting the composite material and to obtain a material with one or more transparent or non-transparent windows.
- the process does not require bonding or welding of an added transparent part.
- the multilayer composite material comprises an additional intermediate layer between the surface layer and the substrate layer, said intermediate layer comprising a thermoplastic polymer B comprising a window also filled with the thermoplastic material or the thermoplastic plate.
- the present invention relates to a process for manufacturing a multilayer composite material for producing mechanical parts or structured elements or articles, comprising the following steps:
- the process comprises:
- the surface layer comprising the thermoplastic polymer A, for the thermoforming is in the form of a film or plate.
- Said film or plate has a thickness of less than 10 mm, preferably less than 6 mm.
- the process comprises:
- the plate inserted in the window(s) is transparent and allows light transmission of greater than 65%, preferably greater than 75% and more preferably greater than 85%.
- step a) The cutting out in step a) is performed in a single step after superposition of the surface layer and of the fibrous material or separately for the fibrous material and for the surface layer.
- the cutting out in step a) is performed by means of a cutting tool such as scissors, a cutting press, a punch or a laser.
- a cutting tool such as scissors, a cutting press, a punch or a laser.
- the impregnation of the fibrous material in step c) is performed in a closed mold.
- Step c) of impregnating the reinforcing fibrous material with the (meth)acrylic liquid syrup and step d) of polymerizing the (meth)acrylic liquid syrup are performed in the same closed mold.
- surface layer denotes the upper or outer layer of the multilayer composite material exposed to the environment.
- substrate layer denotes the layer comprising the thermoplastic polymeric composite material of the multilayer composite.
- intermediate layer means that this layer is between the surface layer and the substrate layer of the multilayer composite material.
- fibrous material refers to fabrics, webs, felts or nonwovens that may be in the form of strips, laps, braids, locks or pieces.
- the tern “window” as used relates to a cutaway made in the layers forming the composite material and intended to be filled with a thermoplastic material that may be transparent.
- transparent window as used relates to a window filled with a transparent thermoplastic material.
- thermoplastic plate as used means a plate made of thermoplastic polymer.
- transparent means allowing the passage of light of the visible spectrum with light transmission of greater than 65%, according to the light transmission measurements defined by standard ASTM D 1003.
- (meth)acrylic refers to any type of acrylic or methacrylic monomer.
- (meth)acrylic thermoplastic polymer matrix refers to a (meth)acrylic thermoplastic polymer matrix, essentially polymers comprising monomers in a proportion of 50% by weight or more of the (meth)acrylic thermoplastic polymer matrix.
- PMMA refers to homo- and copolymers of methyl methacrylate (MMA), the ratio of MMA in the PMMA being at least 70% by weight for the MMA copolymer.
- the term “monomer” as used refers to a molecule which can undergo polymerization.
- polymerization refers to the process of converting a monomer or a mixture of monomers into a polymer.
- thermoplastic polymer refers to a polymer that turns to a liquid or becomes more liquid or less viscous when heated and that can take on new shapes by the application of heat and pressure (thermoforming). After cooling, the polymer becomes hard and keeps its new modeled shape.
- thermosetting polymer refers to a prepolymer in a liquid, solid or viscous state that changes irreversibly into an unmeltable, insoluble polymeric network by curing.
- polymeric composite refers to a multicomponent material comprising several different phase domains, among which at least one type of phase domain is a continuous phase and in which at least one component is a polymer.
- the structural parts or elements made with the multilayer composite material are panels, lids, shells or parts made of composite material for aircraft, boats (hulls or bridges), wagons, parts of motor vehicles or agricultural machines (bodywork, hoods, doors), and electrical or electronic appliance cases.
- the (meth)acrylic polymer mention may be made of polyalkyl methacrylates or polyalkyl acrylates.
- the (meth)acrylic polymer is polymethyl methacrylate (PMMA).
- PMMA denotes a methyl methacrylate (MMA) homopolymer or copolymer or mixtures thereof.
- the methyl methacrylate (MMA) homo- or copolymer comprises at least 70%, preferably at least 80%, advantageously at least 90% and more advantageously at least 95% by weight of methyl methacrylate.
- the PMMA is a mixture of at least one homopolymer and at least one copolymer of MMA, or a mixture of at least two homopolymers or two copolymers of MMA with a different average molecular weight, or a mixture of at least two copolymers of MMA with a different monomer composition.
- the copolymer of methyl methacrylate comprises from 70% to 99.7% by weight of methyl methacrylate and from 0.3% to 30% by weight of at least one monomer containing at least one ethylenic unsaturation that can copolymerize with methyl methacrylate.
- the comonomer is an alkyl acrylate in which the alkyl group contains from 1 to 4 carbon atoms.
- the copolymer of methyl methacrylate comprises from 80% to 99.7%, advantageously from 90% to 99.7% and more advantageously from 90% to 99.5% by weight of methyl methacrylate and from 0.3% to 20%, advantageously from 0.3% to 10% and more advantageously from 0.5% to 10% by weight of at least one monomer containing at least one ethylenic unsaturation that can copolymerize with methyl methacrylate.
- the comonomer is chosen from methyl acrylate and ethyl acrylate, or mixtures thereof.
- the weight-average molecular weight of the (meth)acrylic polymer should be high, meaning larger than 50 000 g/mol, preferably larger than 100 000 g/mol.
- the weight-average molecular weight may be measured by steric exclusion chromatography (SEC) or gel permeation chromatography (GPC).
- SEC steric exclusion chromatography
- GPC gel permeation chromatography
- the polymers are dissolved at 1 g/l in BHT-stabilized THF.
- the calibration is performed using monodisperse polystyrene standards.
- the monomer is chosen from acrylic acid, methacrylic acid, alkyl acrylic monomers, alkyl methacrylic monomers and mixtures thereof.
- the monomer is chosen from acrylic acid, methacrylic acid, alkyl acrylic monomers, alkyl methacrylic monomers and mixtures thereof, the alkyl group containing from 1 to 22 linear, branched or cyclic carbons; the alkyl group preferably containing from 1 to 12 linear, branched or cyclic carbons.
- the (meth)acrylic monomer is chosen from methyl methacrylate, ethyl methacrylate, methyl acrylate, ethyl acrylate, methacrylic acid, acrylic acid, n-butyl acrylate, isobutyl acrylate, n-butyl methacrylate, isobutyl methacrylate, cyclohexyl acrylate, cyclohexyl methacrylate, isobornyl acrylate and isobornyl methacrylate, and mixtures thereof.
- the (meth)acrylic monomer is chosen from methyl methacrylate, isobornyl acrylate and acrylic acid, and mixtures thereof.
- At least 50% by weight and preferably at least 60% by weight of the monomer is methyl methacrylate.
- At least 50% by weight, preferably at least 60% by weight, more preferably at least 70% by weight, advantageously at least 80% by weight and even more advantageously 90% by weight of the monomer is a mixture of methyl methacrylate with isobornyl acrylate and/or acrylic acid.
- a fibrous substrate comprises fabrics, webs, felts or nonwovens that may be in the form of strips, laps, braids, locks or pieces.
- the fibrous material may have various forms and dimensions, either one-dimensional, two-dimensional or three-dimensional.
- a fibrous substrate comprises an assembly of one or more fibers. When the fibers are continuous, their assembly forms fabrics.
- the one-dimensional form corresponds to linear long fibers.
- the fibers may be discontinuous or continuous.
- the fibers may be arranged randomly or in the form of a continuous filament parallel to each other.
- a fiber is defined by its aspect ratio, which is the ratio between the length and the diameter of the fiber.
- the fibers used in the present invention are long fibers or continuous fibers.
- the fibers have an aspect ratio of at least 1000, preferably at least 1500, more preferably at least 2000, advantageously at least 3000 and more advantageously at least 5000, even more advantageously at least 6000, more advantageously still at least 7500 and most advantageously at least 10 000.
- the two-dimensional form corresponds to nonwoven or woven fibrous mats or reinforcements or bundles of fibers, which may also be braided. Even if the two-dimensional form has a certain thickness and consequently in principle a third dimension, it is considered as two-dimensional according to the present invention.
- the three-dimensional form corresponds, for example, to nonwoven fibrous mats or reinforcements or stacked or folded bundles of fibers or mixtures thereof, an assembly of the two-dimensional form in the third dimension.
- the origins of the fibrous material may be natural or synthetic.
- natural material one can mention plant fibers, wood fibers, animal fibers or mineral fibers.
- Natural fibers are, for example, sisal, jute, hemp, flax, cotton, coconut fibers, and banana fibers.
- Animal fibers are, for example, wool or hair.
- polymeric fibers chosen from fibers of thermosetting polymers, of thermoplastic polymers or mixtures thereof.
- the polymeric fibers may be made of polyamide (aliphatic or aromatic), polyester, polyvinyl alcohol, polyolefins, polyurethanes, polyvinyl chloride, polyethylene, unsaturated polyesters, epoxy resins and vinyl esters.
- the mineral fibers may also be chosen from glass fibers, especially of E, R or S2 type, carbon fibers, boron fibers or silica fibers.
- the fibrous substrate of the present invention is chosen from plant fibers, wood fibers, animal fibers, mineral fibers, synthetic polymeric fibers, glass fibers and carbon fibers, or mixtures thereof.
- the fibrous substrate is chosen from mineral fibers.
- the fibers of the fibrous substrate have a diameter between 0.005 ⁇ m and 100 ⁇ m, preferably between 1 ⁇ m and 50 ⁇ m, more preferably between 5 ⁇ m and 30 ⁇ m and advantageously between 10 ⁇ m and 25 ⁇ m.
- the fibers of the fibrous substrate of the present invention are chosen from continuous fibers (meaning that the aspect ratio does not necessarily apply as for long fibers) for the one-dimensional form, or for long or continuous fibers for the two-dimensional or three-dimensional form of the fibrous substrate.
- the liquid (meth)acrylic syrup according to the invention that impregnates the fibrous substrate, it comprises a (meth)acrylic monomer or a mixture of (meth)acrylic monomers, a (meth)acrylic polymer and at least one initiator or initiating system for starting the polymerization of the (meth)acrylic monomer.
- the viscosity is increased by using a (meth)acrylic monomer or a mixture of a (meth)acrylic monomer with a dissolved (meth)acrylic polymer or a (meth)acrylic polymer. This solution is commonly referred to as “syrup” or “prepolymer”.
- the liquid (meth)acrylic syrup must have a controlled viscosity for the impregnation process of the present invention, especially for correct and total wetting and impregnation of the fibrous substrate.
- the dynamic viscosity of the liquid (meth)acrylic syrup is in a range from 10 mPa*s to 10 000 mPa*s, preferably from 50 mPa*s to 5000 mPa*s and advantageously from 100 mPa*s to 1000 mPa*s.
- the viscosity of the syrup can be readily measured with a rheometer or a viscometer.
- the dynamic viscosity is measured at 25° C.
- the liquid (meth)acrylic syrup has Newtonian behavior, meaning that there is no shear-thinning, so that the dynamic viscosity is independent of the shear in a rheometer or of the speed of the spindle in a viscometer.
- liquid (meth)acrylic syrup does not voluntarily comprise any solvent additives.
- the liquid (meth)acrylic polymer is completely soluble in the (meth)acrylic monomer.
- This (meth)acrylic polymer is PMMA, i.e. the homopolymer or a copolymer of methyl methacrylate (MMA) or a mixture thereof as defined previously.
- PMMA i.e. the homopolymer or a copolymer of methyl methacrylate (MMA) or a mixture thereof as defined previously.
- the (meth)acrylic monomer is the same as defined previously.
- the (meth)acrylic monomer(s) are present in a proportion of 40% by weight in the liquid (meth)acrylic syrup, preferably 50% by weight, advantageously 60% by weight and more advantageously 65% by weight of the total amount of the (meth)acrylic syrup.
- the polymer(s) of the liquid (meth)acrylic syrup are present in a proportion of at least 10% by weight and more advantageously of at least 20% by weight of the total amount of the (meth)acrylic syrup.
- the polymer(s) of the liquid (meth)acrylic syrup are present in a proportion of not more than 60% by weight, preferably not more than 50%, advantageously not more than 40% and more advantageously not more than 35% by weight of the total amount of the liquid (meth)acrylic syrup.
- the process for manufacturing composite parts is chosen from resin transfer molding and infusion.
- Resin transfer molding is a process using a two-sided mold set which forms both surfaces of a composite material.
- the lower side is a rigid mould.
- the upper side can be a rigid or flexible mould.
- Flexible molds can be made from composite materials, silicone or extruded polymer films such as nylon. The two sides fit together to form a mold cavity.
- the distinguishing feature of resin transfer molding is that the fibrous substrate is placed into this cavity and the mold set is closed prior to the introduction of the liquid (meth)acrylic syrup.
- Resin transfer molding includes numerous varieties which differ in the mechanics of introduction of the liquid (meth)acrylic syrup into the fibrous substrate in the mold cavity. These variations range from vacuum infusion to vacuum assisted resin transfer molding (VARTM). This process may be performed at room or elevated temperature.
- VARTM vacuum assisted resin transfer molding
- the liquid (meth)acrylic syrup must have the appropriate viscosity for this process for preparing the polymeric composite material.
- the liquid (meth)acrylic syrup is sucked into the fibrous substrate, which is in a special mold, by applying a gentle vacuum.
- the fibrous substrate is infused and completely impregnated by the liquid (meth)acrylic syrup.
- Another subject of the invention relates to a multilayer composite material comprising:
- the window or each window is filled with a transparent thermoplastic plate made of PET (polyethylene terephthalate), or of polycarbonate, polystyrene or, preferably, PMMA (polymethyl methacrylate).
- PET polyethylene terephthalate
- PMMA polymethyl methacrylate
- the composite material comprises an additional intermediate layer ( 3 ) between the surface layer ( 1 ) and the substrate layer ( 2 ), said intermediate layer comprising a thermoplastic polymer B.
- thermoplastic polymer A of the surface layer may be chosen from the polymers of the following list:
- the surface layer may also comprise mixtures of two or more polymers of the above list of thermoplastic polymers.
- the thermoplastic polymer A may comprise fillers or additives.
- Additives that may be mentioned include organic additives such as impact modifiers or block copolymers, heat stabilizers, flame-retarding elements, and mixtures thereof.
- thermoplastic polymer A of the surface layer is chosen from (meth)acrylic polymers, acrylonitrile-styrene-acrylate (ASA) copolymer, polyvinylidene fluoride (PVDF) and polycarbonate (PC), or mixtures thereof.
- ASA acrylonitrile-styrene-acrylate
- PVDF polyvinylidene fluoride
- PC polycarbonate
- thermoplastic polymer A is chosen from (meth)acrylic polymers and preferably PMMA.
- thermoplastic polymer A of the surface layer may be in the form of a film, a plate or a sheet.
- thermoplastic polymer B of the intermediate layer may be chosen from the polymers of the following list:
- the polymer of the intermediate layer may also comprise mixtures of two or more polymers B of the above list of polymers B, for example, mixtures of PET/PC, of PMMA/PLA or ABS/PC mixtures.
- thermoplastic polymer B of the intermediate layer may comprise fillers or additives.
- Additives that may be mentioned include organic additives such as impact modifiers or block copolymers, heat stabilizers, UV stabilizers, flame-retarding elements, and mixtures thereof.
- thermoplastic polymer B is chosen from (meth)acrylic polymers, acrylonitrile-butadiene-styrene (ABS) copolymer, acrylonitrile-styrene-acrylate (ASA) copolymer, polyvinylidene fluoride (PVDF) and polycarbonate (PC), or mixtures thereof.
- ABS acrylonitrile-butadiene-styrene
- ASA acrylonitrile-styrene-acrylate
- PVDF polyvinylidene fluoride
- PC polycarbonate
- thermoplastic polymer B of the intermediate layer is an ABS or ASA.
- thermoplastic polymer B of the surface layer may be in the form of a film, a plate or a sheet.
- thermoplastic (meth)acrylic matrix of the substrate layer of the polymeric composite material comprises at least one (meth)acrylic polymer comprising one or more (meth)acrylic monomers.
- the (meth)acrylic monomer(s) represent at least 50% by weight or more, preferably 60% or more, advantageously 70% by weight and even more advantageously 80% by weight of the thermoplastic (meth)acrylic matrix.
- the (meth)acrylic polymer(s) represent at least 80% by weight advantageously at least 90% by weight of the thermoplastic (meth)acrylic matrix.
- thermoplastic (meth)acrylic matrix comprises one or more (meth)acrylic polymers.
- the (meth)acrylic polymer mention may be made of polyalkyl methacrylate or polyalkyl acrylate.
- the (meth)acrylic polymer is a polyalkyl meth acrylate.
- the composite part is especially a motor vehicle part, boat part, train part, sport article, plane or helicopter part, space ship or rocket part, photovoltaic module part, wind turbine part, furniture part, construction or building part, telephone or cellphone part, computer or television part, or printer or photocopier part.
- FIG. 1 is a diagram of a cross section AA of a multilayer composite material with a surface layer ( 1 ) comprising a thermoplastic polymer A, a substrate layer comprising a polymeric composite material ( 2 ) and a window 10 filled with a transparent thermoplastic material ( 20 ) in the thermoplastic polymer and substrate layers according to one subject of the invention.
- the transparent thermoplastic material is obtained via a transparent thermoplastic plate or by polymerization of the fibrous-substrate impregnation syrup.
- FIG. 2 is a diagram of a cross section of a multilayer composite material, comprising an additional intermediate layer ( 3 ) between the surface layer ( 1 ) and the substrate layer ( 2 ), said intermediate layer comprising a thermoplastic polymer B, the transparent thermoplastic material ( 20 ) filling the window passing through the layers ( 1 ), ( 3 ) and the substrate ( 2 ).
- FIG. 3 is a perspective view of the material viewed in cross section in FIG. 1 .
- FIG. 4 is a view in cross section of a multilayer composite material according to the invention, comprising a window 10 comprising a non-transparent thermoplastic plate ( 21 ).
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Laminated Bodies (AREA)
- Reinforced Plastic Materials (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FR1352057 | 2013-03-07 | ||
FR1352057A FR3002877B1 (fr) | 2013-03-07 | 2013-03-07 | Procede de fabrication d'un materiau composite multicouche, materiau composite multicouche obtenu par le procede et pieces ou structures mecaniques realisees avec ledit materiau. |
PCT/FR2014/050518 WO2014135810A2 (fr) | 2013-03-07 | 2014-03-07 | Procédé de fabrication d'un matériau composite multicouche, matériau composite multicouche obtenu par le procédé et pièces ou structures mécaniques réalisées avec ledit matériau |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/FR2014/050518 A-371-Of-International WO2014135810A2 (fr) | 2013-03-07 | 2014-03-07 | Procédé de fabrication d'un matériau composite multicouche, matériau composite multicouche obtenu par le procédé et pièces ou structures mécaniques réalisées avec ledit matériau |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/997,026 Continuation US11040504B2 (en) | 2013-03-07 | 2018-06-04 | Method for producing a multilayer composite material, multilayer composite material obtained by the method and mechanical parts or structures produced with said material |
Publications (1)
Publication Number | Publication Date |
---|---|
US20150375464A1 true US20150375464A1 (en) | 2015-12-31 |
Family
ID=48795653
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/772,101 Abandoned US20150375464A1 (en) | 2013-03-07 | 2014-03-07 | Method for producing a multilayer composite material, multilayer composite material obtained by the method and mechanical parts or structures produced with said material |
US15/997,026 Active 2035-02-24 US11040504B2 (en) | 2013-03-07 | 2018-06-04 | Method for producing a multilayer composite material, multilayer composite material obtained by the method and mechanical parts or structures produced with said material |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/997,026 Active 2035-02-24 US11040504B2 (en) | 2013-03-07 | 2018-06-04 | Method for producing a multilayer composite material, multilayer composite material obtained by the method and mechanical parts or structures produced with said material |
Country Status (5)
Country | Link |
---|---|
US (2) | US20150375464A1 (fr) |
EP (1) | EP2964452B1 (fr) |
JP (1) | JP7048199B2 (fr) |
FR (1) | FR3002877B1 (fr) |
WO (1) | WO2014135810A2 (fr) |
Families Citing this family (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR3002943B1 (fr) | 2013-03-11 | 2015-03-27 | Arkema France | Sirop (meth)acrylique liquide d'impregnation d'un substrat fibreux, procede d'impregnation d'un substrat fibreux, materiau composite obtenu apres polymerisation dudit substrat pre-impregne. |
FR3002942B1 (fr) | 2013-03-11 | 2016-01-22 | Arkema France | Sirop (meth)acrylique liquide d'impregnation d'un substrat fibreux, procede d'impregnation d'un substrat fibreux, materiau composite obtenu apres polymerisation dudit substrat pre-impregne. |
FR3005057B1 (fr) | 2013-04-25 | 2015-05-15 | Arkema France | Sirop liquide (meth)acrylique, son procede de polymerisation, son utilisation et objet moule obtenu a partir de celui-ci |
WO2017189453A1 (fr) | 2016-04-28 | 2017-11-02 | Natureworks Llc | Structure d'isolation en mousse polymère comportant un revêtement composé d'une feuille multicouche qui contient une couche de polymère résistant à la chaleur et une couche de résine de polylactide |
KR101821362B1 (ko) * | 2016-11-03 | 2018-01-25 | 두원케미칼 주식회사 | 자동차 내장재용 조성물 및 이를 이용한 자동차 내장재용 적층체 |
CN114555662A (zh) * | 2019-06-04 | 2022-05-27 | 阿科玛股份有限公司 | 热塑性凝胶涂料 |
FR3105069B1 (fr) | 2019-12-20 | 2023-08-04 | Arkema France | Composition composite polymérique comprenant deux zones comportant différents renforcements, son procédé de fabrication, son utilisation et article le comprenant |
Citations (14)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20020046517A1 (en) * | 2000-07-31 | 2002-04-25 | Asahi Glass Company, Limited | Vehicular resinous window and vehicular door panel |
US20020106952A1 (en) * | 2000-12-29 | 2002-08-08 | Nokia Corporation | Resin injection molded article with reinforcing or decorative core |
US20040185733A1 (en) * | 2001-08-28 | 2004-09-23 | Shoji Murai | Cfrp plate material and method for preparation thereof |
US20070152466A1 (en) * | 2005-12-30 | 2007-07-05 | Shenzhen Futaihong Precision Industrial Co,.Ltd. | Cover for a mobile device, and method for making the cover |
US20070252305A1 (en) * | 2006-05-01 | 2007-11-01 | Taiwan Green Point Enterprises Co., Ltd. | Double-injection molding method |
DE102006049913A1 (de) * | 2006-10-18 | 2008-04-24 | Schmuhl Faserverbundtechnik Gmbh & Co. Kg | Formteil mit einer dekorativen und/oder funktionellen Oberfläche und Verfahren zu seiner Herstellung sowie deren Verwendung |
US20080122137A1 (en) * | 2005-03-10 | 2008-05-29 | Koichi Hamaoka | Method of Manufacturing Casing for Electronic Apparatus |
US20090009942A1 (en) * | 2007-07-04 | 2009-01-08 | Shenzhen Futaihong Precision Industry Co., Ltd. | Housing for electronic devices, electronic device using the housing and method for making the housing |
US20090061145A1 (en) * | 2007-08-30 | 2009-03-05 | Chi Mei Communication Systems, Inc. | Dual-injection molding article and method for making same |
US20090218725A1 (en) * | 2008-02-29 | 2009-09-03 | Symbol Technologies, Inc. | Injection molded paneled mobile device enclosure |
JP2011126213A (ja) * | 2009-12-20 | 2011-06-30 | Nihon Press Kogyo Kk | 窓構造体の製造方法 |
US20110222214A1 (en) * | 2010-03-12 | 2011-09-15 | Shenzhen Futaihong Precision Industry Co., Ltd. | Housing of an electronic device and method for making same |
WO2012136235A1 (fr) * | 2011-04-02 | 2012-10-11 | Daimler Ag | Élément de carrosserie multicouches renforcé de fibres et son procédé de fabrication |
US20150352818A1 (en) * | 2013-01-15 | 2015-12-10 | Arkema France | Multilayer composite composition, its manufacturing process, and article obtained thereof |
Family Cites Families (22)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2322582A (en) * | 1940-06-14 | 1943-06-22 | Pittsburgh Plate Glass Co | Laminated glass |
BE556399A (fr) | 1956-04-18 | |||
FR1256929A (fr) | 1960-05-13 | 1961-03-24 | Continental Can Co | Procédé de fabrication de pièces tubulaires par laminage et gonflage et billettes pour la mise en oeuvre de ce procédé |
JPS5638225A (en) * | 1979-09-07 | 1981-04-13 | Asahi Fiber Glass Co Ltd | Preparation of frp frame body with window |
JPS61225013A (ja) * | 1985-03-29 | 1986-10-06 | Fukubi Kagaku Kogyo Kk | 透視性電磁波遮蔽材の製法 |
US5961900A (en) * | 1992-10-10 | 1999-10-05 | Wedi; Helmut | Method of manufacturing composite board |
JPH06182781A (ja) * | 1992-12-17 | 1994-07-05 | Toyota Motor Corp | 枠付樹脂体の製造方法 |
JPH08207556A (ja) | 1995-01-31 | 1996-08-13 | Isuzu Motors Ltd | 自動車のfrpルーフの明り取り構造 |
JP2001058329A (ja) * | 1999-08-20 | 2001-03-06 | Sumitomo Chem Co Ltd | 繊維強化成形品の製造方法 |
JP4255744B2 (ja) | 2003-05-07 | 2009-04-15 | 本田技研工業株式会社 | 動作補助装置の制御システム |
US8262823B2 (en) * | 2003-09-04 | 2012-09-11 | The Boeing Company | Window skin panel and method of making same |
US7976947B2 (en) | 2005-08-10 | 2011-07-12 | Dupont Polymer Powders Switzerland Sarl | Article of manufacture comprising surfaces of thermoplastic composites coated with a powder coating composition |
FR2936524B1 (fr) * | 2008-09-26 | 2010-09-24 | Arkema France | Article plat transparent a base de materiaux acryliques nanostructures |
US9120272B2 (en) * | 2010-07-22 | 2015-09-01 | Apple Inc. | Smooth composite structure |
JP5742155B2 (ja) * | 2010-09-30 | 2015-07-01 | 大日本印刷株式会社 | 化粧シート |
JP2012179892A (ja) * | 2010-10-19 | 2012-09-20 | Nitto Denko Corp | 高難燃ポリマー部材、難燃性物品及び難燃化方法 |
BRPI1005235A2 (pt) | 2010-12-27 | 2013-04-16 | Mvc Componentes Plasticos Ltda | aperfeiÇoamento de qualidade superficial de compositos |
JP2012206348A (ja) * | 2011-03-29 | 2012-10-25 | Toray Coatex Co Ltd | 繊維強化abs系樹脂材料及び成形体 |
US20140221568A1 (en) * | 2011-07-20 | 2014-08-07 | Nippon Shokubai Co., Ltd. | Molding material |
FR2981652B1 (fr) | 2011-10-21 | 2015-03-27 | Arkema France | Composites via la polymerisation in-situ de resines thermoplastiques methacryliques |
JP5909078B2 (ja) * | 2011-11-09 | 2016-04-26 | 日本化薬株式会社 | 紫外線硬化型樹脂組成物、硬化物及び物品 |
FR2993581B1 (fr) | 2012-07-18 | 2016-01-22 | Arkema France | Procede d'impregnation pour un substrat fibreux, sirop (meth)acrylique liquide pour le procede d'impregnation, son procede de polymerisation et produit structure obtenu a partir de celui-ci |
-
2013
- 2013-03-07 FR FR1352057A patent/FR3002877B1/fr not_active Expired - Fee Related
-
2014
- 2014-03-07 JP JP2015560751A patent/JP7048199B2/ja active Active
- 2014-03-07 WO PCT/FR2014/050518 patent/WO2014135810A2/fr active Application Filing
- 2014-03-07 EP EP14715039.5A patent/EP2964452B1/fr active Active
- 2014-03-07 US US14/772,101 patent/US20150375464A1/en not_active Abandoned
-
2018
- 2018-06-04 US US15/997,026 patent/US11040504B2/en active Active
Patent Citations (14)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20020046517A1 (en) * | 2000-07-31 | 2002-04-25 | Asahi Glass Company, Limited | Vehicular resinous window and vehicular door panel |
US20020106952A1 (en) * | 2000-12-29 | 2002-08-08 | Nokia Corporation | Resin injection molded article with reinforcing or decorative core |
US20040185733A1 (en) * | 2001-08-28 | 2004-09-23 | Shoji Murai | Cfrp plate material and method for preparation thereof |
US20080122137A1 (en) * | 2005-03-10 | 2008-05-29 | Koichi Hamaoka | Method of Manufacturing Casing for Electronic Apparatus |
US20070152466A1 (en) * | 2005-12-30 | 2007-07-05 | Shenzhen Futaihong Precision Industrial Co,.Ltd. | Cover for a mobile device, and method for making the cover |
US20070252305A1 (en) * | 2006-05-01 | 2007-11-01 | Taiwan Green Point Enterprises Co., Ltd. | Double-injection molding method |
DE102006049913A1 (de) * | 2006-10-18 | 2008-04-24 | Schmuhl Faserverbundtechnik Gmbh & Co. Kg | Formteil mit einer dekorativen und/oder funktionellen Oberfläche und Verfahren zu seiner Herstellung sowie deren Verwendung |
US20090009942A1 (en) * | 2007-07-04 | 2009-01-08 | Shenzhen Futaihong Precision Industry Co., Ltd. | Housing for electronic devices, electronic device using the housing and method for making the housing |
US20090061145A1 (en) * | 2007-08-30 | 2009-03-05 | Chi Mei Communication Systems, Inc. | Dual-injection molding article and method for making same |
US20090218725A1 (en) * | 2008-02-29 | 2009-09-03 | Symbol Technologies, Inc. | Injection molded paneled mobile device enclosure |
JP2011126213A (ja) * | 2009-12-20 | 2011-06-30 | Nihon Press Kogyo Kk | 窓構造体の製造方法 |
US20110222214A1 (en) * | 2010-03-12 | 2011-09-15 | Shenzhen Futaihong Precision Industry Co., Ltd. | Housing of an electronic device and method for making same |
WO2012136235A1 (fr) * | 2011-04-02 | 2012-10-11 | Daimler Ag | Élément de carrosserie multicouches renforcé de fibres et son procédé de fabrication |
US20150352818A1 (en) * | 2013-01-15 | 2015-12-10 | Arkema France | Multilayer composite composition, its manufacturing process, and article obtained thereof |
Non-Patent Citations (3)
Title |
---|
Machine Translation of DE 102006049913 A1, 04/2008 * |
Machine Translation of JP 2011126213 A, 06/2011 * |
Machine Translation of WO 2012136235 A1, 10/2012 * |
Also Published As
Publication number | Publication date |
---|---|
EP2964452A2 (fr) | 2016-01-13 |
JP2016514062A (ja) | 2016-05-19 |
WO2014135810A2 (fr) | 2014-09-12 |
EP2964452B1 (fr) | 2017-04-19 |
FR3002877A1 (fr) | 2014-09-12 |
JP7048199B2 (ja) | 2022-04-05 |
US20180281320A1 (en) | 2018-10-04 |
US11040504B2 (en) | 2021-06-22 |
FR3002877B1 (fr) | 2015-03-27 |
WO2014135810A3 (fr) | 2014-11-20 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US11040504B2 (en) | Method for producing a multilayer composite material, multilayer composite material obtained by the method and mechanical parts or structures produced with said material | |
KR102290810B1 (ko) | 다층 복합재 조성물 이의 제조 방법 및 이로부터 수득된 물품 | |
EP2985135B1 (fr) | Matériau composite obtenu par polymérisation in situ de résines (méth)acryliques thermoplastiques et son utilisation | |
KR102282890B1 (ko) | 섬유질 기재의 함침 방법, 함침 방법용 액체 (메트)아크릴 시럽, 그것의 중합 방법 및 그에 의해 수득된 구조화 물품 | |
US10683405B2 (en) | Liquid (meth)acrylic syrup for impregnating a fibrous substrate, method of impregnating a fibrous substrate, composite material obtained following polymerisation of the pre-impregnated substrate | |
JP2016513741A (ja) | 繊維性基材を含浸するための液体(メタ)アクリルシロップ、繊維性基材を含浸するための方法、及びこのプレ含浸基材の重合後に製造された複合材料 | |
JP7096834B2 (ja) | 熱可塑性ポリマー複合材部品を製造するための方法、及び前記方法により得られる物体 | |
US20210403653A1 (en) | Acrylic composites with improved surface properties | |
JP2015139984A (ja) | 木質化粧板の製造方法 | |
CN106459433B (zh) | 官能纤维基材的浸渍方法、用于浸渍方法的液体单体浆料、其聚合方法和由其获得的结构化制品 | |
EP2945800B1 (fr) | Composition composite multicouche, son procédé de fabrication et article obtenu de cette composition | |
US20230348677A1 (en) | Polymeric composite composition comprising two zones with different reinforcement, its process of manufacturing, its use and article comprising it |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: ARKEMA FRANCE, FRANCE Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:GERARD, PIERRE;REEL/FRAME:037100/0618 Effective date: 20151103 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |