US20170137982A1 - Nonwoven - Google Patents

Nonwoven Download PDF

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Publication number
US20170137982A1
US20170137982A1 US15/350,252 US201615350252A US2017137982A1 US 20170137982 A1 US20170137982 A1 US 20170137982A1 US 201615350252 A US201615350252 A US 201615350252A US 2017137982 A1 US2017137982 A1 US 2017137982A1
Authority
US
United States
Prior art keywords
fibers
nonwoven
plies
web
binder
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
Application number
US15/350,252
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English (en)
Inventor
Jose Portoles
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Epsilon Composite SA
Original Assignee
Epsilon Composite SA
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Epsilon Composite SA filed Critical Epsilon Composite SA
Assigned to EPSILON COMPOSITE reassignment EPSILON COMPOSITE ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PORTOLES, JOSE
Publication of US20170137982A1 publication Critical patent/US20170137982A1/en
Abandoned legal-status Critical Current

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Classifications

    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/083—Combinations of continuous fibres or fibrous profiled structures oriented in one direction and reinforcements forming a two dimensional structure, e.g. mats
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—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 by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H11/00—Non-woven pile fabrics
    • D04H11/08—Non-woven pile fabrics formed by creation of a pile on at least one surface of a non-woven fabric without addition of pile-forming material, e.g. by needling, by differential shrinking
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/12—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding

Definitions

  • the present invention relates to a nonwoven composed of several superposed fiber plies.
  • the holding together of these various plies may pose a problem, especially if the nonwoven is used for producing pultruded profiles.
  • multiaxial reinforcements which are produced either by weaving, or by laying down of plies stitched together in order to form multiaxial nonwovens, in this case, the solidity (cohesion and maintaining of the angles during the processing) of the nonwoven depends on the stitching.
  • These multiaxial reinforcements have the drawback of being fragile during their processing and particularly for the processing by pultrusion where it is necessary to pull on the multiaxial reinforcements and make them pass through a die. In particular, these multiaxial reinforcements become distorted and when the angles are initially 45° and 90°, these angles are no longer maintained after the processing. The mechanical characteristics of these profiles are then greatly reduced.
  • the yarns are bound at the stitch point but may move easily between the stitch points (spaced for example 5 to 10 mm apart), since there are few bonding points between the fibers.
  • the stitches give rise to a deformation of the fiber ply to allow the needle to pass through, thus creating a hole which may be annoying on the one hand if a certain surface protection is desired for the possible electrical performance and/or the surface homogeneity, and on the other hand which may misalign the fibers leading to losses of the mechanical characteristics.
  • the fibers may also be covered with thermoplastic or thermosetting powder in order to bind the yarns by points.
  • thermoplastic or thermosetting powder in order to bind the yarns by points.
  • the use of powder makes it necessary to calibrate the amount of product to use and to eliminate the surplus.
  • the invention proposes to produce nonwovens that eliminate these drawbacks, a process for producing this type of nonwoven and also the profile obtained with this nonwoven.
  • the nonwoven according to the invention consists of superposed plies of fibers, it is characterized in that a binder web is positioned between two plies and heat sealed, and that it is not stitched.
  • the heat sealing of the plies makes the nonwoven extremely solid and sets the orientation of the fibers which can no longer move during the processing of the nonwoven.
  • the fibers are, in fact, held by weld points that are non-continuous and are distributed over the entire surface, unlike stitching.
  • the fact that the nonwoven is not stitched makes it possible to guarantee a constant orientation of the fibers with no discontinuity.
  • the nonwoven is a pultrusion nonwoven.
  • This nonwoven is particularly suitable for pultrusion since it is not pierced by stitching and has a dense distribution of weld points of the fibers which are thus particularly well immobilized.
  • the plies consist of oriented fibers.
  • the heat sealing makes it possible to have more bonding points between the fibers and therefore to guarantee a better hold of these fibers in particular when these fibers are oriented.
  • two superposed plies have different fiber orientations.
  • the profiles have a better strength if nonwovens with fibers of opposite orientations are used.
  • the binder web is a thermoplastic.
  • the advantage provided by these thermoplastic webs is that of improving the impact resistance of the composite obtained.
  • the nonwoven comprises a surface web.
  • a surface web which may be a glass mat or a polymer web
  • functions of protection asgainst galvanic corrosion, against abrasion, etc.
  • the surface web should not be pierced and cannot therefore be stitched.
  • the binder web has a melting point above a pultrusion temperature.
  • the binder web which may be a thermoplastic, will be chosen to have a melting point above the temperature used during the pultrusion process so as to avoid a degradation of the nonwoven during the pultrusion operation.
  • the binder web has a basis weight less than or equal to the basis weight of the fibers of the plies.
  • the nonwoven should remain permeable in order to enable the pultrusion.
  • the basis weight of the binder webs or of the thermoplastics should be low enough to enable a good impregnation of the fibers but high enough to avoid any movement of the fibers after heat sealing.
  • the basis weight of the binder web or of the thermoplastic depends on the basis weight of the fibers; it should be less than 10% of the basis weight of the fibers, preferably less than 5%. For example, a basis weight between 4 and 8 g/m 2 makes it possible to heat seal plies of 100 to 300 g/m 2 of carbon.
  • certain yarns are reinforcing fibers.
  • These fibers may be made of carbon, of glass fibers, of aramid (KevlarTM), etc.
  • the invention also relates to a process for producing a nonwoven that consists in superposing plies of fibers and at least one binder web between two plies of fibers, then in heat sealing the assembly.
  • a surface web is positioned on the plies of fibers before the heat sealing.
  • the surface web should be counted in the layers to be taken into account during the heat sealing operation.
  • the reinforcing fiber layers are all heat sealed in a single go. However it is possible to repeat this operation several times in order to attain the desired stack of plies, for example a reinforcing web may thus be heat sealed to a pre-existing multiaxial reinforcement.
  • the invention also relates to a pultruded profile comprising a nonwoven with at least one of the preceding features.
  • the pultruded profile uses a nonwoven obtained according to the process.
  • the profile thus obtained is particularly suitable for aeronautical uses which are particularly demanding.
  • FIG. 1 is a stitched nonwoven according to the prior art
  • FIG. 2 is a schematic view of a nonwoven according to the invention
  • FIG. 3 is a top view of a nonwoven according to the invention.
  • the nonwoven from the prior art illustrated in FIG. 1 here consists of four plies 1, 2, 3 and 4 of fibers 10, 20, 30 and 40 that are superposed and stitched together by stitching 5 .
  • the fibers of a same ply are parallel to one another.
  • the plies are oriented differently on each layer.
  • the vertical fibers in FIG. 1 are in the pull direction, that is to say that they make an angle of 0° .
  • the fibers 20 of the ply 2 therefore make an angle of 90°.
  • the fibers 20 of the second ply 2 are positioned on the fibers 10 of the first ply 1 oriented with an angle of 45°.
  • the third ply 3 is positioned on the second ply 2 and its fibers 30 are positioned with an angle of ⁇ 45° relative to the fibers 40 .
  • the fourth ply 4 has fibers 40 positioned at 0°, i.e. along the length of the nonwoven.
  • the stitching 5 creates bonding points between the plies in a linear and spaced out manner.
  • the stitching 5 ′ is more sinuous.
  • the fibers are bound at the stitch point but may move easily between the stitch points which are in general spaced 5 to 10 mm apart.
  • the nonwoven is quadraxial (with angles of 45°, 90°, ⁇ 45° and 0°) and its solidity depends on the stitching. But when there is no 0° in the nonwoven, the tensile strength decreases greatly and is very low in the case where there is only +and ⁇ 45°.
  • the ply 2 consists of fibers 20 having an angle of 0°
  • the plies 1 and 3 consist of fibers 10 and 30 having angles of +or ⁇ 45°.
  • Each ply is separated from the next by a binder web 6 .
  • the nonwoven illustrated in FIG. 3 consists of two plies 1 and 3 oriented at + or ⁇ 45°, and an inserted binder web 6 .
  • this web 6 which will be heat sealed, covers a large portion of each ply 1 and 3 , there will therefore be a large number of bonding points of the fibers of each ply rendering the various layers firmly attached.
  • the web 6 will preferably be very thin in order to make it possible to produce a multitude of micro-bondings preventing the fibers 10 and 30 from moving.
  • the nonwoven has only two layers (2 plies) but it is possible to add other layers by (optionally) inserting other binder webs 6 .
US15/350,252 2015-11-12 2016-11-14 Nonwoven Abandoned US20170137982A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR1560839A FR3043700B1 (fr) 2015-11-12 2015-11-12 Non tisse
FR1560839 2015-11-12

Publications (1)

Publication Number Publication Date
US20170137982A1 true US20170137982A1 (en) 2017-05-18

Family

ID=54848843

Family Applications (1)

Application Number Title Priority Date Filing Date
US15/350,252 Abandoned US20170137982A1 (en) 2015-11-12 2016-11-14 Nonwoven

Country Status (4)

Country Link
US (1) US20170137982A1 (fr)
EP (1) EP3168353A1 (fr)
JP (1) JP2017089089A (fr)
FR (1) FR3043700B1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020126771A1 (fr) 2018-12-19 2020-06-25 Structil S.A. Procédé de fabrication d'un produit par pultrusion et appareil pour exécuter un tel procédé
CN112638611A (zh) * 2018-08-27 2021-04-09 赛峰短舱公司 用于制造具有双曲率几何结构的复合板的复合预成型件的制造方法

Family Cites Families (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0129263Y2 (fr) * 1985-03-12 1989-09-06
FR2716466B1 (fr) * 1994-02-24 1996-04-12 Chomarat & Cie Armature textile utilisable pour la réalisation de complexes stratifiés.
DE19809264C2 (de) * 1998-03-04 2003-06-26 Eldra Kunststofftechnik Gmbh Fasergelegeanordnung und Verfahren zur Herstellung eines Vorformlings
EP1175998A4 (fr) * 1999-04-08 2006-01-11 Mitsubishi Rayon Co Preforme destinee a un materiau composite et un tel materiau
AU6648500A (en) * 1999-06-21 2001-01-09 Pella Corporation Pultruded part and method of preparing a reinforcement mat for the part
JP4126978B2 (ja) * 2001-07-06 2008-07-30 東レ株式会社 プリフォームおよびそれからなるｆｒｐならびにｆｒｐの製造方法
AU2002366559A1 (en) * 2001-12-11 2003-06-23 Pella Corporation Reinforcing mat for a pultruded part
FR2837844B1 (fr) * 2002-04-02 2004-09-03 Chomarat Composites Nouveau produit de renfort
US20040219855A1 (en) * 2003-05-02 2004-11-04 Tsotsis Thomas K. Highly porous interlayers to toughen liquid-molded fabric-based composites
JP2005313455A (ja) * 2004-04-28 2005-11-10 Toho Tenax Co Ltd 多軸織物及びその製造方法、プリフォーム材、繊維強化プラスチック成形品
US8163122B1 (en) * 2006-08-18 2012-04-24 Flsmidth A/S Multidirectional filament reinforced tape and method of manufacture
CA2793166C (fr) * 2010-03-18 2017-07-04 Toho Tenax Europe Gmbh Tissus multiaxiaux presentant des non-tisses polymeres

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112638611A (zh) * 2018-08-27 2021-04-09 赛峰短舱公司 用于制造具有双曲率几何结构的复合板的复合预成型件的制造方法
WO2020126771A1 (fr) 2018-12-19 2020-06-25 Structil S.A. Procédé de fabrication d'un produit par pultrusion et appareil pour exécuter un tel procédé

Also Published As

Publication number Publication date
FR3043700B1 (fr) 2018-12-07
JP2017089089A (ja) 2017-05-25
FR3043700A1 (fr) 2017-05-19
EP3168353A1 (fr) 2017-05-17

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Date Code Title Description
AS Assignment

Owner name: EPSILON COMPOSITE, FRANCE

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:PORTOLES, JOSE;REEL/FRAME:040815/0234

Effective date: 20161216

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION