WO1992002357A1 - Fabrication of fiber reinforced thermoplastics, with non-woven felt - Google Patents

Fabrication of fiber reinforced thermoplastics, with non-woven felt Download PDF

Info

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
method
fibres
non
used
woven
Prior art date
Application number
PCT/US1990/004436
Other languages
French (fr)
Inventor
Marinus De Jager
Eugen Karl Moessner
Original Assignee
General Electric Company
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 General Electric Company filed Critical General Electric Company
Priority to PCT/US1990/004436 priority Critical patent/WO1992002357A1/en
Publication of WO1992002357A1 publication Critical patent/WO1992002357A1/en

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29BPREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10Coating or impregnating independently of the moulding or shaping step
    • B29B15/105Coating 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/40Shaping or impregnating by compression not applied
    • B29C70/42Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46Shaping 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
    • B29C70/465Shaping 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING 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
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12Condition, 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
    • B29K2105/128Condition, 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING 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
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/25Solid

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.
PCT/US1990/004436 1990-08-08 1990-08-08 Fabrication of fiber reinforced thermoplastics, with non-woven felt WO1992002357A1 (en)

Priority Applications (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

Applications Claiming Priority (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
JP51135290A JPH05500781A (en) 1990-08-08 1990-08-08

Publications (1)

Publication Number Publication Date
WO1992002357A1 true WO1992002357A1 (en) 1992-02-20

Family

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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)

* Cited by examiner, † Cited by third party
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 thermoplastic material and manufacturing METHOD
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)

* Cited by examiner, † Cited by third party
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

Patent Citations (4)

* Cited by examiner, † Cited by third party
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)

* Cited by examiner, † Cited by third party
Title
RESEARCH DISCLOSURE 20239, February 1981. *

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
MY119800A (en) * 1997-07-11 2005-07-29 Novartis Ag Pyridine derivatives
US6656957B1 (en) 1997-07-11 2003-12-02 Novartis Ag Pyridine derivatives
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
NL1010706C2 (en) * 1998-12-02 2001-08-15 Ten Cate Advanced Composites B A method for manufacturing a dimensionally stable fabric cloth, as well as thus obtained fabric cloth.
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 thermoplastic material and manufacturing METHOD
RU2465140C2 (en) * 2007-02-13 2012-10-27 Эйрбас Оперейшнз Лимитед Method of processing composite material
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
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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