WO1992002357A1 - Fabrication of fiber reinforced thermoplastics, with non-woven felt - Google Patents
Fabrication of fiber reinforced thermoplastics, with non-woven felt Download PDFInfo
- Publication number
- WO1992002357A1 WO1992002357A1 PCT/US1990/004436 US9004436W WO9202357A1 WO 1992002357 A1 WO1992002357 A1 WO 1992002357A1 US 9004436 W US9004436 W US 9004436W WO 9202357 A1 WO9202357 A1 WO 9202357A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fibres
- woven
- synthetic resin
- fibre
- reinforcing fibres
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
- B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
- B29B15/10—Coating or impregnating independently of the moulding or shaping step
- B29B15/105—Coating or impregnating independently of the moulding or shaping step of reinforcement of definite length with a matrix in solid form, e.g. powder, fibre or sheet form
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
- B29C70/465—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating by melting a solid material, e.g. sheets, powders of fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
- B29K2105/128—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles in the form of a mat
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/25—Solid
Definitions
- the invention relates to a method of manufac- turing fibre-reinforced laminates of thermoplastic synthetic resin.
- reinforcing fibres may be impregnated with a polymer solution.
- the disadvantage of this method is that it can be used only with thermoplasts for which suitable solvents are available, and furthermore, after the impregnation, com ⁇ paratively large quantities of solvent have to be removed or recovered.
- Another possibility is the impregnation of the reinforcing fibres with a so-called "melting-film" .
- the method requires a high degree of technical process know-how to obtain a good impregnation at higher melt viscosity of the thermoplastic resin without adversely influencing the mechanical properties of the reinforcing fibres.
- Still another technique is the powder impregnation, in which the yarns are spread and simultaneously contacted with a bed of fluidised resin powder. The yarn with the powder adhered thereto is then heated so that the polymer melts and adheres to the fibre. The assembly is then compacted under pressure and cooled.
- the powder must have a grain cross-section in the same order of magnitude as the reinforcing filaments.
- This cross- -section is approximately 10 micrometres for carbon fibres and aramide fibres, and only few thermoplastic resins are available as such a fine powder.
- thermoplastic material is laid on a layer of reinforcing fibres and the assembly is then compressed at elevated pressure and temperature.
- thermoplastic resin in fibre form with reinforcing fibres, namely in the form of a mixed fabric or of a mixed fibre.
- the resulting product is a fabric which comprises either filaments of the two materials, for example, one material in the warp and the other one in the weft, or a fabric of the mixed fibres.
- the thermoplastic resin must be available in yarn form.
- the method according to the invention is characterised in that the synthetic resin in the form of at least one layer of non-woven fibre product is com ⁇ bined with at least one layer of reinforcing fibres and the layers are combined while using thermal energy and pressure.
- the non-woven fibre product of the ther ⁇ moplastic resin further serves only as an intermediate product, so that the cohesion of the fibres is not too critical.
- thermoplastic resins may be chosen, for example, polyalkenes (for example, the various types of polyethene, polypropene, polystyrene), polycarbonates, polyether imides, polyesters (for example, polyethylene terephthalate or polybutylene terephthalate) , polypheny- lene ethers, thermoplastic elastomers, rubber-modified polymers, on the basis of styrene, for example, HIPS and ABS or mixtures of one or more of these polymers.
- polyalkenes for example, the various types of polyethene, polypropene, polystyrene
- polycarbonates for example, polyethylene terephthalate or polybutylene terephthalate
- polyesters for example, polyethylene terephthalate or polybutylene terephthalate
- polypheny- lene ethers for example, polypheny- lene ethers
- thermoplastic elastomers for example, polypheny- lene
- non-woven fibre pro ⁇ ducts The processing to form non-woven fibre pro ⁇ ducts is done in a manner known per se by spinning and laying the fibres as a mat or felt. .
- Long or short fibres may optionally be manufactured, short fibres being pre ⁇ ferred.
- the polymer may be extruded in the conventional manner through a spin-die and the fibres may be stretched and be laid as a non- -woven length. After this they are usually calendered.
- Short fibres may suitably be formed by means of the so- -called blast drawing process. In this process the polymer is spun while blowing with hot air, after which the emanating material is cooled directly with cold air. As a result of this a flow of short fibres is formed which are laid on a drum while forming a non- -woven length of fibres or felt.
- the flow of short fibres may alternatively be provided (moulded) directly on the layer of reinforcing fibres. It is also possible to spin the fibres from a solution, the solution being subjected to a rapid evaporation. Short fibres are obtained in this manner also, but this method is to be preferred less because in this case solvent has to be removed or recovered.
- the reinforcing fibres used may be the conven ⁇ tionally used fibres, in particular glass, aramide and carbon.
- the reinforcing fibres may be formed to a fabric or a knitting. It is also possible to use the rein- forcing fibres in the form of a non-woven of continuous or short fibres.
- thermoplastic resin and reinforcing fibres are simply laid one on top of the other, the layers are heated to the melting-point of the thermoplastic material, the assembly is compressed to obtain a com- pacted r, iterial and the assembly is then allowed to cool under pressure to a temperature below the Tg value of the thermoplastic material.
- the present method has several advan ⁇ tages.
- the resin content of the rexn- forcing fibres can be very readily controlled.
- this problem could well be avoided by using a solution of the poly ⁇ mers, but this has for its disadvantage that large quan- tities of solvent would have to be removed or recovered.
- An excellent impregnation without a solvent is obtained by means of the present method.
- Another disadvantage of the known method is that cavities often occur in the compacted material.
- residues of solvent may be present in the impregnated material. Of course, this is excluded in the present method.
- a non-woven felt of short polypropene fibres was manufactured by blast drawing.
- One layer hereof was provided on a glass fibre fabric and two or three of these two-layer combinations were laid one on top of the other and heated under pressure in a flat press. In this simple manner a glass-fibre-reinforced polypropene lami ⁇ nate of a good quality was obtained without any problems occurring.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Reinforced Plastic Materials (AREA)
- Laminated Bodies (AREA)
Abstract
A novel process has been developed enabling the manufacture of shaped articles out of fibre reinforced thermoplastics. The process enables the incorporation of major amount of glass fibres by first manufacturing a flat sheet out of one or more layers of reinforcing fibres and one or more layers of fibres out of the thermoplastic resin. In a subsequent step the obtained flat sheet is pressed into a shaped article.
Description
"FABRICATION OF FIBER REINFORCED THERMOPLASTICS , WITH NON-WOVEN FELT"
Method of manufacturing fibre-reinforced laminates of thermoplastic synthetic resin, as well products obtained by using the method.
The invention relates to a method of manufac- turing fibre-reinforced laminates of thermoplastic synthetic resin.
various methods are known for the manufacture of this type of products. For example, reinforcing fibres may be impregnated with a polymer solution. The disadvantage of this method is that it can be used only with thermoplasts for which suitable solvents are available, and furthermore, after the impregnation, com¬ paratively large quantities of solvent have to be removed or recovered. Another possibility is the impregnation of the reinforcing fibres with a so-called "melting-film" . Although all thermoplastic resins can be processed herewith, the method requires a high degree of technical process know-how to obtain a good impregnation at higher melt viscosity of the thermoplastic resin without adversely influencing the mechanical properties of the reinforcing fibres. Still another technique is the powder impregnation, in which the yarns are spread and simultaneously contacted with a bed of fluidised resin powder. The yarn with the powder adhered thereto
is then heated so that the polymer melts and adheres to the fibre. The assembly is then compacted under pressure and cooled.
The disadvantage of this is that the powder must have a grain cross-section in the same order of magnitude as the reinforcing filaments. This cross- -section is approximately 10 micrometres for carbon fibres and aramide fibres, and only few thermoplastic resins are available as such a fine powder.
The so far conventionally used method in prac¬ tice is that a thin or thick foil of thermoplastic material is laid on a layer of reinforcing fibres and the assembly is then compressed at elevated pressure and temperature. For this purpose it is hence necessary first to manufacture a foil of the thermoplastic material, for example, by extrusion.
For completeness' sake it is to be noted that it is also known to combine the thermoplastic resin in fibre form with reinforcing fibres, namely in the form of a mixed fabric or of a mixed fibre. In this case the resulting product is a fabric which comprises either filaments of the two materials, for example, one material in the warp and the other one in the weft, or a fabric of the mixed fibres. A requirement for this is, of course, that the thermoplastic resin must be available in yarn form.
An extremely advantageous and simple method has now been found surprisingly for the manufacture of fibre-reinforced laminates of thermoplastic synthetic resin. It is just in connection with the many methods which were already known in this field and the fact that they have been in use for decades, that it
is extra surprising that such a simple and extremely practical method has now been found.
The method according to the invention is characterised in that the synthetic resin in the form of at least one layer of non-woven fibre product is com¬ bined with at least one layer of reinforcing fibres and the layers are combined while using thermal energy and pressure.
This method has several advantages. It is to be noted in particular that the method is simple to per¬ form and that the thickness of the resulting laminate per unit by weight can be readily controlled by using the method. This is much more difficult when a pre¬ viously extruded synthetic resin foil is used.
The non-woven fibre product of the ther¬ moplastic resin further serves only as an intermediate product, so that the cohesion of the fibres is not too critical.
As thermoplastic resins may be chosen, for example, polyalkenes (for example, the various types of polyethene, polypropene, polystyrene), polycarbonates, polyether imides, polyesters (for example, polyethylene terephthalate or polybutylene terephthalate) , polypheny- lene ethers, thermoplastic elastomers, rubber-modified polymers, on the basis of styrene, for example, HIPS and ABS or mixtures of one or more of these polymers.
The processing to form non-woven fibre pro¬ ducts is done in a manner known per se by spinning and laying the fibres as a mat or felt.. Long or short fibres may optionally be manufactured, short fibres being pre¬ ferred.
In the case of long fibres the polymer may be extruded in the conventional manner through a spin-die and the fibres may be stretched and be laid as a non- -woven length. After this they are usually calendered. Short fibres may suitably be formed by means of the so- -called blast drawing process. In this process the polymer is spun while blowing with hot air, after which the emanating material is cooled directly with cold air. As a result of this a flow of short fibres is formed which are laid on a drum while forming a non- -woven length of fibres or felt.
The flow of short fibres may alternatively be provided (moulded) directly on the layer of reinforcing fibres. It is also possible to spin the fibres from a solution, the solution being subjected to a rapid evaporation. Short fibres are obtained in this manner also, but this method is to be preferred less because in this case solvent has to be removed or recovered.
The reinforcing fibres used may be the conven¬ tionally used fibres, in particular glass, aramide and carbon. The reinforcing fibres may be formed to a fabric or a knitting. It is also possible to use the rein- forcing fibres in the form of a non-woven of continuous or short fibres.
The manufacture of the present laminates is extremely simple and this is one of the most important advantages of the present invention.
The desired number of layers of non-woven fibre product of the thermoplastic resin and reinforcing fibres are simply laid one on top of the other, the layers are heated to the melting-point of the thermoplastic material, the assembly is compressed to obtain a com-
pacted r, iterial and the assembly is then allowed to cool under pressure to a temperature below the Tg value of the thermoplastic material.
As compared with the known method of manufac¬ turing laminates, the present method has several advan¬ tages. As already stated, the resin content of the rexn- forcing fibres can be very readily controlled. Furthermore, when using the known methods, it is often difficult to obtain a good impregnation of the rein¬ forcing fibres due to the high viscosity of the ther¬ moplastic polymers. As already stated, this problem could well be avoided by using a solution of the poly¬ mers, but this has for its disadvantage that large quan- tities of solvent would have to be removed or recovered. An excellent impregnation without a solvent is obtained by means of the present method.
Another disadvantage of the known method is that cavities often occur in the compacted material.
This is not the case in the method according to the pre¬ sent invention.
In several of the known methods residues of solvent may be present in the impregnated material. Of course, this is excluded in the present method.
EXAMPLE
A non-woven felt of short polypropene fibres was manufactured by blast drawing. One layer hereof was provided on a glass fibre fabric and two or three of these two-layer combinations were laid one on top of the other and heated under pressure in a flat press. In this simple manner a glass-fibre-reinforced polypropene lami¬ nate of a good quality was obtained without any problems occurring.
Claims
CLAIMS : 1. A method of manufacturing fibre-reinforced laminates of thermoplastic synthetic resin, charac¬ terised in that the synthetic resin in the form of at least one layer of non-woven fibre product is combined with at least one layer of reinforcing fibres and the layers are combined while using thermal energy and pressure.
2. A method as claimed in Claim 1, characterised in that a non-woven fibre product having short fibres is used.
3. A method as claimed in Claim 2, characterised in that a fibre product is used which has been obtained by blast drawing.
4. A method as claimed in Claims 1-3, charac- terised in that a polyalkene, polycarbonate, polyether imide, polyester, polyphenylene ether, thermoplastic elastomer, rubber-modified polymer on the basis of styrene or a mixture of one or more of these polymers is used as a thermoplastic synthetic resin.
5. A method as claimed in Claims 1-4, charac¬ terised in that reinforcing fibres of glass, aramide or carbon are used.
6. A method as claimed in Claim 5, characterised in that reinforcing fibres in the form of a fabric or knitting or in the form of a non-woven are used.
7. Products obtained while using the method as claimed in one or more of the preceding Claims.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/US1990/004436 WO1992002357A1 (en) | 1990-08-08 | 1990-08-08 | Fabrication of fiber reinforced thermoplastics, with non-woven felt |
| JP2511352A JPH05500781A (en) | 1990-08-08 | 1990-08-08 | Method for manufacturing fiber-reinforced thermoplastic synthetic resin using non-woven felt |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/US1990/004436 WO1992002357A1 (en) | 1990-08-08 | 1990-08-08 | Fabrication of fiber reinforced thermoplastics, with non-woven felt |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO1992002357A1 true WO1992002357A1 (en) | 1992-02-20 |
Family
ID=22220988
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US1990/004436 WO1992002357A1 (en) | 1990-08-08 | 1990-08-08 | Fabrication of fiber reinforced thermoplastics, with non-woven felt |
Country Status (2)
| Country | Link |
|---|---|
| JP (1) | JPH05500781A (en) |
| WO (1) | WO1992002357A1 (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1005979A2 (en) * | 1998-12-02 | 2000-06-07 | Ten Cate Advanced Composites B.V. | Method for manufacturing a dimensionally stable fabric cloth and fabric cloth obtained therewith |
| FR2789045A1 (en) * | 1999-02-03 | 2000-08-04 | Bird | CYCLE FRAME OF THERMOPLASTIC MATERIAL AND MANUFACTURING METHOD THEREOF |
| US6656957B1 (en) | 1997-07-11 | 2003-12-02 | Novartis Ag | Pyridine derivatives |
| WO2008099207A1 (en) * | 2007-02-13 | 2008-08-21 | Airbus Uk Limited | Method of processing a composite material |
| EP2716435A1 (en) * | 2012-10-02 | 2014-04-09 | Reifenhäuser GmbH & Co. KG Maschinenfabrik | Method and semi-finished product for producing a composite moulded part, in particular a fibre compound moulded part and composite moulded part, in particular fibre compound moulded part |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3717528A (en) * | 1970-02-05 | 1973-02-20 | Gen Mills Inc | Fabric bonding with thermoplastic fibrous mats |
| US3837995A (en) * | 1972-04-24 | 1974-09-24 | Kimberly Clark Co | Autogenously bonded composite web |
| US4410385A (en) * | 1981-01-28 | 1983-10-18 | General Electric Company | Method of making a composite article |
| US4799985A (en) * | 1984-03-15 | 1989-01-24 | Hoechst Celanese Corporation | Method of forming composite fiber blends and molding same |
-
1990
- 1990-08-08 WO PCT/US1990/004436 patent/WO1992002357A1/en unknown
- 1990-08-08 JP JP2511352A patent/JPH05500781A/en active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3717528A (en) * | 1970-02-05 | 1973-02-20 | Gen Mills Inc | Fabric bonding with thermoplastic fibrous mats |
| US3837995A (en) * | 1972-04-24 | 1974-09-24 | Kimberly Clark Co | Autogenously bonded composite web |
| US4410385A (en) * | 1981-01-28 | 1983-10-18 | General Electric Company | Method of making a composite article |
| US4799985A (en) * | 1984-03-15 | 1989-01-24 | Hoechst Celanese Corporation | Method of forming composite fiber blends and molding same |
Non-Patent Citations (1)
| Title |
|---|
| RESEARCH DISCLOSURE 20239, February 1981. * |
Cited By (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6656957B1 (en) | 1997-07-11 | 2003-12-02 | Novartis Ag | Pyridine derivatives |
| MY119800A (en) * | 1997-07-11 | 2005-07-29 | Novartis Ag | Pyridine derivatives |
| NL1010706C2 (en) * | 1998-12-02 | 2001-08-15 | Ten Cate Advanced Composites B | Method for manufacturing a dimensionally stable tissue cloth, as well as tissue cloth obtained therewith. |
| EP1005979A2 (en) * | 1998-12-02 | 2000-06-07 | Ten Cate Advanced Composites B.V. | Method for manufacturing a dimensionally stable fabric cloth and fabric cloth obtained therewith |
| EP1005979A3 (en) * | 1998-12-02 | 2001-08-29 | Ten Cate Advanced Composites B.V. | Method for manufacturing a dimensionally stable fabric cloth and fabric cloth obtained therewith |
| WO2000046098A1 (en) * | 1999-02-03 | 2000-08-10 | Bird | Bicycle frame in thermoplastic material and method for making same |
| FR2789045A1 (en) * | 1999-02-03 | 2000-08-04 | Bird | CYCLE FRAME OF THERMOPLASTIC MATERIAL AND MANUFACTURING METHOD THEREOF |
| WO2008099207A1 (en) * | 2007-02-13 | 2008-08-21 | Airbus Uk Limited | Method of processing a composite material |
| RU2465140C2 (en) * | 2007-02-13 | 2012-10-27 | Эйрбас Оперейшнз Лимитед | Method of processing composite material |
| EP2716435A1 (en) * | 2012-10-02 | 2014-04-09 | Reifenhäuser GmbH & Co. KG Maschinenfabrik | Method and semi-finished product for producing a composite moulded part, in particular a fibre compound moulded part and composite moulded part, in particular fibre compound moulded part |
| WO2014053566A1 (en) * | 2012-10-02 | 2014-04-10 | Reifenhäuser GmbH & Co. KG Maschinenfabrik | Method for producing a semi-finished product and semi-finished product for production of a composite molded part, in particular a composite fiber molded part and composite molded part, in particular a composite fiber molded part |
| CN104853893A (en) * | 2012-10-02 | 2015-08-19 | 赖芬豪泽机械工厂有限及两合有限公司 | Method for producing a semi-finished product and semi-finished product for production of a composite molded part, in particular a composite fiber molded part and composite molded part, in particular a composite fiber molded part |
| EP3263303A1 (en) * | 2012-10-02 | 2018-01-03 | Reifenhäuser GmbH & Co. KG Maschinenfabrik | Method for generating a semifinished product for producing a composite form part, in particular a fibre compound form part |
| KR101834052B1 (en) | 2012-10-02 | 2018-03-02 | 라이펜호이저 게엠베하 운트 코. 카게 마쉬넨파브릭 | Method for producing a semi-finished product and semi-finished product for production of a composite molded part, in particular a composite fiber molded part and composite molded part, in particular a composite fiber molded part |
| US10392483B2 (en) | 2012-10-02 | 2019-08-27 | Reifenhaeuser Gmbh & Co. Kg Maschinenfabrik | Semifinished product for making molded composite part and method of making same |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH05500781A (en) | 1993-02-18 |
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