WO1998035086A1 - Mat made of fibres of different materials, composite body produced therewith and process for producing parts made of such composite bodies - Google Patents

Mat made of fibres of different materials, composite body produced therewith and process for producing parts made of such composite bodies Download PDF

Info

Publication number
WO1998035086A1
WO1998035086A1 PCT/IB1997/000078 IB9700078W WO9835086A1 WO 1998035086 A1 WO1998035086 A1 WO 1998035086A1 IB 9700078 W IB9700078 W IB 9700078W WO 9835086 A1 WO9835086 A1 WO 9835086A1
Authority
WO
WIPO (PCT)
Prior art keywords
fibers
mat
fiber strands
composite body
mat according
Prior art date
Application number
PCT/IB1997/000078
Other languages
German (de)
French (fr)
Inventor
Bernd-Uwe Wulf
Original Assignee
Symalit Ag
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 Symalit Ag filed Critical Symalit Ag
Priority to EP97900719A priority Critical patent/EP0958420A1/en
Priority to PCT/IB1997/000078 priority patent/WO1998035086A1/en
Publication of WO1998035086A1 publication Critical patent/WO1998035086A1/en

Links

Classifications

    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/08—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 structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • 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
    • B29C70/086—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 and with one or more layers of pure plastics material, e.g. foam layers
    • 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
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
    • 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
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/06—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 structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • 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
    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • 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
    • D04H1/542—Adhesive fibres
    • D04H1/544—Olefin series
    • 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
    • D04H13/00—Other non-woven fabrics
    • 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
    • D04H3/10—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 yarns or filaments made mechanically
    • 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
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/12—Glass fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • 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
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/02—Synthetic macromolecular particles
    • B32B2264/0214—Particles made of materials belonging to B32B27/00
    • B32B2264/0257—Polyolefin particles, e.g. polyethylene or polypropylene homopolymers or ethylene-propylene copolymers
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • 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
    • B32B2605/003—Interior finishings

Definitions

  • the present invention relates to a mat which has fibers made of different materials and to a thermally deformable composite body produced from this mat. It further relates to a method for producing such a mat, a method for producing such a composite body and a method for producing a component from such a composite body.
  • Composite bodies in particular made of a fiber-reinforced plastic, are used for the longer to replace materials such as wood and metal.
  • Parts of road vehicles in which, for example, parts of the seats, dashboards, parts of the bumpers, etc. are made from fiber-reinforced thermoplastic materials can be mentioned as a non-exhaustive example. Specifically, for example, glass fiber reinforced polypropylene.
  • the glass fibers should be soaked with polypropylene, for example, so that every single fiber is completely covered by the thermoplastic material, so that the glass fibers are firmly embedded in the polypropylene and the polypropylene is distributed homogeneously in the respective component.
  • polypropylene for example, so that every single fiber is completely covered by the thermoplastic material, so that the glass fibers are firmly embedded in the polypropylene and the polypropylene is distributed homogeneously in the respective component.
  • the known composite bodies made of fiber-reinforced thermoplastic are successful and satisfactory, there is a desire for an even less impregnation of the glass fibers, an even better covering of the same by the polypropylene, for an even more homogeneous distribution of the plastic in the composite. body, and also after an even more rational manufacture of the composite body.
  • the aim of the invention is to show a mat made of fibers, which is composed of first fibers made of a first material and second fibers made of a second material, at least some of the fibers being in the form of fiber strands made of fibers made of the first material and made of Fibers made of the second material are present, and which, when processed into a composite body, enables an extremely complete impregnation of the fibers made of the first material with the second material, and allows the first fibers to be properly encased by the second material, which second material is completely homogeneous in the Composite body is distributed.
  • the mat according to the invention is characterized by the features of claim 1.
  • the thermally deformable composite body produced from at least one mat is characterized by the features of claim 14.
  • a method for manufacturing the mat is characterized by the features of claim 9 and a method for manufacturing the thermally deformable composite body by the features of claim 16.
  • a method for producing a component from the thermally deformable composite body is characterized by the features of claim 18.
  • FIG. 2 is a view of part of a mat formed from fiber strands
  • FIG. 3 shows a view of a composite body produced from the mat according to FIG. 2
  • FIG. 4 shows a mat formed from fiber strands and additional individual fibers
  • 5 shows a mat with a carrier layer formed from fibers
  • FIG. 6 shows a mat with a carrier layer formed from a film
  • FIG. 7 schematically shows a device for producing the composite body according to FIG. 3,
  • FIG. 8 shows a production variant
  • FIG. 9 schematically shows a molding tool for producing a component from a blank cut out of the composite body according to FIG. 4.
  • first fibers 1 shows a cross section through a fiber strand 3 which has a multiplicity of first fibers 1 made of a first material, for example glass, and a multiplicity of second fibers 2 made of a second material, for example polypropylene.
  • the first fibers 1 can alternatively consist of carbon, aramid, boron, steel, PEEK (polyether ether ketone), PAN (high-strength polyacrylonitrile), flax, hemp, salis, jute, ramie, coconut and kenaf, this list is not final.
  • the second fibers 2 can alternatively consist of thermoplastics, such as PP (polypropylene), PE (polyethylene), PA (polyamide), PET (polyethylene terephthalate) and / or mixtures of these thermoplastics. This list is also not exhaustive.
  • Fiber strands 3 which contain fibers 1 made of, for example, glass and fibers 2 made of, for example, polypropylene, are freely available on the market and therefore do not have to be described in detail.
  • a coherent mat is formed from a large number of the fiber strands 3 mentioned above.
  • the fiber strands are placed in an endless or cut form on a flat surface. The underlying surface is laid and connected and solidified with one another in such a way that a mat is created.
  • connection can be made by means of a needle known per se, with which a form-fitting connection of the individual fiber strands 3 is achieved to form a mat-shaped random fleece.
  • chemical or thermal bonding is also provided. Only the fibers of one material have to be connected. It is assumed that the material of the second individual fibers 2 is a thermoplastic, e.g. Is polypropylene.
  • the melting point of this second material is much lower than the melting point of the first material.
  • bonding in particular with thermal bonding, only the second material is heated and thus brought into a molten state, and thus the molten polypropylene fibers, for example, melt together at their contact points.
  • the glass fibers are not affected in any way. If an individual fiber strand is approximately rectilinear or only slightly curved, the individual glass fibers can be pulled out very easily, since they are arranged so as to be slidable relative to the polypropylene fibers in the fiber strand. In the finally formed mat, the glass fibers can still be pulled out individually, but this would be necessary due to this. the many strong curvatures of a greater application of force, so that the glass fibers practically do not shift during further processing to form the composite body, although there is no actual bond between the glass fibers.
  • the glass fibers are preferably connected to one another at their contact points, and the same conditions apply to the polypropylene fibers that were described above in connection with the thermal bonding for the glass fibers.
  • a section of the mat 4 (for example in the form of a random fleece) is shown schematically in FIG. 2. This mat 4 consists exclusively of fiber strands 3 held together. This mat 4 can now, for example when rolled up, be transported very easily and can be entered into corresponding devices in the form of webs in processing plants.
  • FIG. 7 schematically shows parts of a plant for producing a composite body from at least one mat 4 made of fiber strands 3.
  • the mat 4 is fed in a continuous processing process in the direction of arrow A to a first zone of the plant, which has, for example, a double belt press 5. Pressure and temperature are exerted on the mat 4 in this double belt press 5.
  • the thermoplastic material e.g. PP melted and penetrates the other fibers, e.g.
  • thermoplastic material is not from the outside, i.e. penetrate into the mat from the two main surfaces, but must be more or less evenly distributed within the mat, respectively. is arranged in the individual fiber strands of the mat, there is an excellent distribution of the thermoplastic material in the mat.
  • the mat is solidified under cooling and pressure to form a compact, here web-shaped composite body 7. This composite body 7 is shown schematically in FIG.
  • Fig. 3 shown. It has glass fibers 1 arranged in a tangled arrangement in a matrix 8 made of plastic are arranged so that there is now a thermally deformable composite body 7.
  • the thickness of this composite body 7 is smaller than the thickness of the original mat 4.
  • glass fibers are placed on a respective base and processed into a mat 4.
  • the processing can be done by means of needles or cohesive connection techniques.
  • Such a mat 4 which is needled as an example, is shown in FIG. 4. It therefore has fiber strands 3 made of glass and PP fibers and additionally fibers 10 made of glass, that is glass fibers.
  • the additional fibers 10 consist of PP.
  • the glass fibers are advantageously deposited in the form of known glass rovings and the PP fibers in the form of multifilaments.
  • additional polypropylene can be added to the mat 4 only immediately before it enters the double belt press.
  • This variant is drawn in FIG. 8.
  • additional polypropylene is fed in the form of one (or more) film web (s) 15, or also in the form of (at least) a melt film.
  • film web (s) 15 or also in the form of (at least) a melt film.
  • Needling should therefore be reduced to a minimum.
  • the mat that is ultimately to be processed into a composite body must still be able to be handled and be transportable.
  • the fiber strands 3 are placed on a tangled nonwoven 13 (also called nonwoven in technical terminology) made of PP (that is, not needled to one another) and only fixed on the tangled nonwoven 13 with the minimum number of needle sticks required for the subsequent handling, as drawn in FIG. 5.
  • a tangled nonwoven 13 also called nonwoven in technical terminology
  • PP that is, not needled to one another
  • a thin PP film web 14 a PP film
  • the connection between the fiber strands 3 and the film web 14 takes place by means of minimal needling.
  • the random fleece 13 can also consist of glass fibers, that is to say the first material.
  • the composite body 7 can now be made into final components, e.g. for road vehicles. Reference is made to FIG. 9.
  • Blanks 9 corresponding to the component to be manufactured are produced from the composite body 7. Depending on the subsequent processing, only a single blank 9 or multiple blanks are used together in the form of a blank structure.
  • the blank structure consisting of a blank 9 or more blanks corresponds in weight to the weight of the finished part of the component to be manufactured.
  • the blanks 9 are reheated in a known manner in a continuous manner in heaters, for example infrared ovens, so that the thermoplastic component of the blank structure from one or more blanks 9 again becomes flowable. Then a respective heated blank structure or blank 9 is inserted into a molding tool, which has, for example, a female mold 11 and a male mold 12, and the molding tool is closed, as indicated by the arrow B. The blank is pressed under pressure in the molding tool and then cooled, so that the component to be produced is finally shaped.
  • heaters for example infrared ovens

Abstract

A mat (4) is formed by needle bonding or thermobonding fibre hanks (3) which contain individual glass fibres (1) and individual thermoplastic fibres (2). The mat is shaped under pressure and heat to form a composite body (7) which contains glass fibres (1) in a homogeneous thermoplastic matrix (8). This composite body can in turn be shaped to form parts made of glass fibre-reinforced plastics.

Description

Matte aus Fasern unterschiedlicher Materialien, daraus hergestellter Verbundkörper und Verfahren zur Herstellung eines Bauteils aus einem solchen VerbundkörperMat made of fibers of different materials, composite body produced therefrom and method for producing a component from such a composite body
Die vorliegende Erfindung betrifft eine Matte, die Fasern aus unterschiedlichen Materialien aufweist sowie einen aus dieser Matte hergestellten, thermisch verformbaren Verbundkörper. Sie betrifft weiter ein Verfahren zur Herstellung einer solchen Matte, ein Verfahren zur Herstellung eines solchen Verbundkörpers sowie ein Verfahren zur Herstellung eines Bauteils aus einem solchen Verbundkörper. Verbundkörper, insbesondere aus einem faserverstärkten Kunststoff, werden je länger je mehr zum Ersetzen von Materialien wie Holz und Metall verwendet. Als nicht abschliessendes Beispiel können Teile von Strassen- fahrzeugen genannt werden, bei welchen beispielsweise Teile der Sitze, Armaturenbretter, Teile der Stossfänger, etc. aus faserverstärkten thermoplastischen Kunststoffen hergestellt sind. Konkret zu nennen ist beispielsweise glasfaserverstärktes Polypropylen.The present invention relates to a mat which has fibers made of different materials and to a thermally deformable composite body produced from this mat. It further relates to a method for producing such a mat, a method for producing such a composite body and a method for producing a component from such a composite body. Composite bodies, in particular made of a fiber-reinforced plastic, are used for the longer to replace materials such as wood and metal. Parts of road vehicles in which, for example, parts of the seats, dashboards, parts of the bumpers, etc. are made from fiber-reinforced thermoplastic materials can be mentioned as a non-exhaustive example. Specifically, for example, glass fiber reinforced polypropylene.
Bei glasfaserverstärktem Polypropylen und ähnlichen Produkten aus faserverstärkten, thermoplastischen Kunststoffen sollten z.B. die Glasfasern vom z.B. Polypropylen möglichst vollständig durchtränkt sein, so dass jede einzelne Faser durch den thermoplastischen Kunststoff vollständig umhüllt ist, so dass die Glasfa- sern fest im Polypropylen eingebettet sind und das Polypropylen im jeweiligen Bauteil homogen verteilt ist. Währenddem die bekannten Verbundkörper aus faserverstärktem thermoplastischen Kunststoff erfolgreich und zufriedenstellend sind, besteht das Bestreben nach einer noch in- nigeren Durchtränkung der Glasfasern, einer noch besseren Umhüllung derselben durch das Polypropylen, nach einer noch homogeneren Verteilung des Kunststoffes im Verbund- körper, und auch nach einem noch rationelleren Herstellen des Verbundkörpers.In the case of glass-fiber reinforced polypropylene and similar products made of fiber-reinforced, thermoplastic materials, for example, the glass fibers should be soaked with polypropylene, for example, so that every single fiber is completely covered by the thermoplastic material, so that the glass fibers are firmly embedded in the polypropylene and the polypropylene is distributed homogeneously in the respective component. While the known composite bodies made of fiber-reinforced thermoplastic are successful and satisfactory, there is a desire for an even less impregnation of the glass fibers, an even better covering of the same by the polypropylene, for an even more homogeneous distribution of the plastic in the composite. body, and also after an even more rational manufacture of the composite body.
Ziel der Erfindung ist eine Matte aus Fasern zu zeigen, die aus ersten Fasern aus einem ersten Mate- rial und aus zweiten Fasern aus einem zweiten Material zusammengesetzt ist, wobei mindestens ein Teil der Fasern in Form von Fasernsträngen aus Fasern aus dem ersten Material und aus Fasern aus dem zweiten Material vorliegt, und die beim Verarbeiten zu einem Verbundkörper eine äu- sserst vollständige Durchtränkung der Fasern aus dem ersten Material durch das zweite Material ermöglicht, eine einwandfreie Umhüllung der ersten Fasern durch das zweite Material erlaubt, welches zweite Material vollständig homogen im Verbundkörper verteilt ist. Die erfindungsgemässe Matte ist gekennzeichnet durch die Merkmale des Anspruchs 1.The aim of the invention is to show a mat made of fibers, which is composed of first fibers made of a first material and second fibers made of a second material, at least some of the fibers being in the form of fiber strands made of fibers made of the first material and made of Fibers made of the second material are present, and which, when processed into a composite body, enables an extremely complete impregnation of the fibers made of the first material with the second material, and allows the first fibers to be properly encased by the second material, which second material is completely homogeneous in the Composite body is distributed. The mat according to the invention is characterized by the features of claim 1.
Der aus mindestens einer Matte hergestellte thermisch verformbare Verbundkörper ist gekennzeichnet durch die Merkmale des Anspruch 14. Ein Verfahren zur Herstellung der Matte ist durch die Merkmale des Anspruch 9 und ein Verfahren zur Herstellung des thermisch verformbaren Verbundkörpers durch die Merkmale des Anspruch 16 gekennzeichnet. Ein Verfahren zur Herstellung eines Bauteils aus dem thermisch verformbaren Verbundkörper ist durch die Merkmale des Anspruch 18 gekennzeichnet.The thermally deformable composite body produced from at least one mat is characterized by the features of claim 14. A method for manufacturing the mat is characterized by the features of claim 9 and a method for manufacturing the thermally deformable composite body by the features of claim 16. A method for producing a component from the thermally deformable composite body is characterized by the features of claim 18.
Nachfolgend wird der Erfindungsgegenstand anhand der Zeichnungen beispielsweise näher erläutert. Es zeigt:The subject matter of the invention is explained in more detail below with reference to the drawings, for example. It shows:
Fig. 1 einen Schnitt durch einen aus zwei verschiedenartigen Fasern gebildeten Faserstrang,1 shows a section through a fiber strand formed from two different types of fibers,
Fig. 2 eine Ansicht eines Teiles einer aus Fasersträngen gebildeten Matte,2 is a view of part of a mat formed from fiber strands,
Fig. 3 eine Ansicht eines aus der Matte nach Fig. 2 hergestellten Verbundkörpers, Fig. 4 eine aus Fasersträngen und zusätzlichen einzelnen Fasern gebildete Matte, Fig. 5 eine Matte mit einer aus Fasern gebildeten Trägerschicht,3 shows a view of a composite body produced from the mat according to FIG. 2, FIG. 4 shows a mat formed from fiber strands and additional individual fibers, 5 shows a mat with a carrier layer formed from fibers,
Fig. 6 eine Matte mit einer aus einer Folie gebildeten Trägerschicht Fig. 7 schematisch eine Vorrichtung zur Herstellung des Verbundkörpers nach Fig. 3,6 shows a mat with a carrier layer formed from a film, FIG. 7 schematically shows a device for producing the composite body according to FIG. 3,
Fig. 8 eine Herstellungsvariante, und Fig. 9 schematisch ein Formwerkzeug zur Herstellung eines Bauteiles aus einem aus dem Verbundkörper nach Fig. 4 ausgeschnittenen Rohling.8 shows a production variant, and FIG. 9 schematically shows a molding tool for producing a component from a blank cut out of the composite body according to FIG. 4.
Die Fig. 1 zeigt einen Querschnitt durch einen Faserstrang 3, der eine Vielzahl erste Fasern 1 aus einem ersten Material, beispielsweise Glas, und eine Vielzahl zweite Fasern 2 aus einem zweiten Material, bei- spielsweise Polypropylen aufweist.1 shows a cross section through a fiber strand 3 which has a multiplicity of first fibers 1 made of a first material, for example glass, and a multiplicity of second fibers 2 made of a second material, for example polypropylene.
Die ersten Fasern 1 können alternativ aus Kohlenstoff, Aramid, Bor, Stahl, PEEK (Polyether-Etherke- ton) , PAN (hochfestes Polyacrylnitril) , Flachs, Hanf, Si- sal, Jute, Ramie, Kokos und Kenaf bestehen, wobei diese Aufzählung nicht abschliessend ist.The first fibers 1 can alternatively consist of carbon, aramid, boron, steel, PEEK (polyether ether ketone), PAN (high-strength polyacrylonitrile), flax, hemp, salis, jute, ramie, coconut and kenaf, this list is not final.
Die zweiten Fasern 2 können alternativ aus Thermoplasten, wie beispielsweise PP (Polypropylen) , PE- (Polyethylen) , PA (Polyamid) , PET (Polyethylenterephtha- lat) und/oder Abmischungen dieser Thermoplaste bestehen. Auch diese Aufzählung ist nicht abschliessend.The second fibers 2 can alternatively consist of thermoplastics, such as PP (polypropylene), PE (polyethylene), PA (polyamide), PET (polyethylene terephthalate) and / or mixtures of these thermoplastics. This list is also not exhaustive.
Faserstränge 3, welche Fasern 1 aus beispielsweise Glas und Fasern 2 aus beispielsweise Polypropylen enthalten, sind auf dem Markt frei erhältlich und müssen somit nicht detailliert beschrieben werden. Um nun einen Körper zu erhalten, der einfach transportiert werden kann und in Verarbeitungsanlagen zu einem für die unterschiedlichsten Zwecke verwendbaren Endprodukt verarbeitet werden kann, wird aus einer Vielzahl der oben genannten Faserstränge 3 eine zusammenhän- gende Matte gebildet. Dazu werden die Faserstränge in einer endlosen oder geschnittenen Form auf eine ebenflä- chige Unterlage gelegt und miteinander derart verbunden und verfestigt, dass eine Matte entsteht.Fiber strands 3, which contain fibers 1 made of, for example, glass and fibers 2 made of, for example, polypropylene, are freely available on the market and therefore do not have to be described in detail. In order to obtain a body that can be easily transported and can be processed in processing plants to form an end product that can be used for a wide variety of purposes, a coherent mat is formed from a large number of the fiber strands 3 mentioned above. To do this, the fiber strands are placed in an endless or cut form on a flat surface. The underlying surface is laid and connected and solidified with one another in such a way that a mat is created.
Diese Verbindung kann mittels einem an sich bekannten Nadeln erfolgen, womit eine formschlüssige Ver- bindung der einzelnen Faserstränge 3 zum Bilden eines mattenförmigen Wirrvlieses erreicht wird. Zusätzlich zum Nadeln oder alternativ dazu ist auch ein chemisches oder thermisches Bonding vorgesehen. Dabei müssen nur die Fasern des einen Materials miteinander verbunden werden. Es sei angenommen, dass das Material der zweiten Einzelfasern 2 ein Thermoplast, z.B. Polypropylen ist .This connection can be made by means of a needle known per se, with which a form-fitting connection of the individual fiber strands 3 is achieved to form a mat-shaped random fleece. In addition to needling or alternatively, chemical or thermal bonding is also provided. Only the fibers of one material have to be connected. It is assumed that the material of the second individual fibers 2 is a thermoplastic, e.g. Is polypropylene.
Der Schmelzpunkt dieses zweiten Materials ist viel tiefer als der Schmelzpunkt des ersten Materials. Beim Bonding, insbesondere bei einem thermischen Bonding wird nur das zweite Material aufgeheizt und damit in einen schmelzflüssigen Zustand gebracht, und somit schmelzen die beispielsweisen schmelzflüssigen Polypropylenfasern an ihren Berührungsstellen zusammen. Die Glasfasern werden jedoch in keiner Weise beeinflusst. Wenn ein einzelner Faserstrang annähernd geradlinig oder nur schwach gekrümmt ist, können die einzelnen Glasfasern sehr einfach herausgezogen werden, da sie relativ zu den Polypropylenfasern im Faserstrang gleitend verschiebbar angeord- net sind. In der endgültig gebildeten Matte können die Glasfasern immer noch einzeln herausgezogen worden, jedoch bedürfte es hierzu aufgrund. der vielen starken Krümmungen einer grösseren Kraftaufwendung, so dass sich die Glasfasern während der weiteren Verarbeitung zum Verbund- körper praktisch nicht verschieben, obwohl keine eigentliche Bindung zwischen den Glasfasern vorhanden ist.The melting point of this second material is much lower than the melting point of the first material. With bonding, in particular with thermal bonding, only the second material is heated and thus brought into a molten state, and thus the molten polypropylene fibers, for example, melt together at their contact points. However, the glass fibers are not affected in any way. If an individual fiber strand is approximately rectilinear or only slightly curved, the individual glass fibers can be pulled out very easily, since they are arranged so as to be slidable relative to the polypropylene fibers in the fiber strand. In the finally formed mat, the glass fibers can still be pulled out individually, but this would be necessary due to this. the many strong curvatures of a greater application of force, so that the glass fibers practically do not shift during further processing to form the composite body, although there is no actual bond between the glass fibers.
Bei einem chemischen Bonding werden vorzugsweise die Glasfasern an ihren Berührungsstellen miteinander verbunden, und für die Polypropylenfasern gelten die- selben Zustände, die oben im Zusammenhang mit dem thermischen Bonding für die Glasfasern beschrieben worden sind. Ein Abschnitt der Matte 4 (beispielsweise in Form eines Wirrvlieses) ist schematisch in der Fig. 2 dargestellt. Diese Matte 4 besteht ausschliesslich aus zusammengehaltenen Fasersträngen 3. Diese Matte 4 kann nun, z.B. aufgerollt, sehr einfach transportiert und in Form von Bahnen in Verarbeitungsanlagen in entsprechende Vorrichtungen eingegeben werden.In the case of chemical bonding, the glass fibers are preferably connected to one another at their contact points, and the same conditions apply to the polypropylene fibers that were described above in connection with the thermal bonding for the glass fibers. A section of the mat 4 (for example in the form of a random fleece) is shown schematically in FIG. 2. This mat 4 consists exclusively of fiber strands 3 held together. This mat 4 can now, for example when rolled up, be transported very easily and can be entered into corresponding devices in the form of webs in processing plants.
In einer solchen Verarbeitungsanlage lässt sich aus der Matte 4 aus Fasersträngen unter Ausübung von Druck und Temperatur ein thermisch verformbarer Verbundkörper herstellen. Dazu ist zu bemerken, dass nur eine einzelne Matte 4 verarbeitet werden kann, oder dass mehrere schichtförmig aufeinandergelegte Matten zu einem einzelnen Verbundkörper verarbeitet werden können. Die Figur 7 zeigt schematisch Teile einer Anlage zur Herstellung eines Verbundkörpers aus mindestens einer Matte 4 aus Fasersträngen 3. Die Matte 4 wird in einem kontinuierlichen Verarbeitungsverfahren in Richtung des Pfeiles A einer ersten Zone der Anlage zugeführt, die beispielsweise eine Doppelbandpresse 5 aufweist. In dieser Doppelbandpresse 5 wird Druck und Temperatur auf die Matte 4 ausgeübt. Damit wird das thermoplastische Material, z.B. PP aufgeschmolzen und durchdringt die anderen Fasern, z.B. Glasfasern, umhüllt dieselben und verteilt sich äusserst homogen. Da das thermoplastische Material nicht von aussen, d.h. von den zwei Hauptflächen der Matte her in dieselbe eindringen .muss, sondern bereits mehr oder weniger gleichmässig verteilt innerhalb der Matte resp. in den einzelnen Fasersträngen der Matte angeordnet ist, ergibt sich eine ausgezeichnete Verteilung des thermoplastischen Materials in der Matte. In einer nachfolgenden Zone 6 der Anlage wird die Matte unter Abkühlen und Druck zu einem kompakten, hier bahnför- migen Verbundkörper 7 verfestigt. Dieser Verbundkörper 7 ist schematisch in derIn a processing plant of this type, a thermally deformable composite body can be produced from the mat 4 from fiber strands while exerting pressure and temperature. It should be noted in this regard that only a single mat 4 can be processed, or that several layers of mats placed on top of one another can be processed to form a single composite body. FIG. 7 schematically shows parts of a plant for producing a composite body from at least one mat 4 made of fiber strands 3. The mat 4 is fed in a continuous processing process in the direction of arrow A to a first zone of the plant, which has, for example, a double belt press 5. Pressure and temperature are exerted on the mat 4 in this double belt press 5. The thermoplastic material, e.g. PP melted and penetrates the other fibers, e.g. Glass fibers, envelops them and is distributed extremely homogeneously. Since the thermoplastic material is not from the outside, i.e. penetrate into the mat from the two main surfaces, but must be more or less evenly distributed within the mat, respectively. is arranged in the individual fiber strands of the mat, there is an excellent distribution of the thermoplastic material in the mat. In a subsequent zone 6 of the plant, the mat is solidified under cooling and pressure to form a compact, here web-shaped composite body 7. This composite body 7 is shown schematically in FIG
Fig. 3 dargestellt. Er weist Glasfasern 1 auf, die in einer wirren Anordnung in einer Matrix 8 aus Kunststoff angeordnet sind, so dass nun ein thermisch verformbarer Verbundkörper 7 vorliegt. Die Dicke dieses Verbundkörpers 7 ist kleiner als die Dicke der ursprünglichen Matte 4. Abhängig von jeweiligen Anwendungen kann es erwünscht sein, das Mischungsverhältnis Glas/PP im Verbundkörper von Fall zu Fall zu variieren, wobei von Fasersträngen 3 ausgegangen wird, die immer dasselbe Verhältnis von Glas zu PP, z.B. 60:40 aufweisen, was offensichtlich die Lagerhaltung sehr vereinfacht, d.h. es müssen nicht ver- schiedene Faserstränge mit unterschiedlichen Glas/PP-Ver- hältnissen in einem Herstellungswerk gelagert werden. Wenn das Endprodukt ein höherer Anteil an Glasfasern aufweisen muss, werden zusätzlich zu den "Standard" Fasersträngen 3 und zusammen mit denselben Glasrovings, Glas- fasern auf eine jeweilige Unterlage abgelegt und zu einer Matte 4 verarbeitet. Das Verarbeiten kann mittels einem Nadeln oder stoffschlüssiger Verbindungstechniken erfolgen. Eine solche Matte 4, die als Beispiel genadelt ist, ist in der Fig. 4 gezeigt. Sie weist also Faserstränge 3 aus Fasern aus Glas und PP auf und zusätzlich Fasern 10 aus Glas, also Glasfasern.Fig. 3 shown. It has glass fibers 1 arranged in a tangled arrangement in a matrix 8 made of plastic are arranged so that there is now a thermally deformable composite body 7. The thickness of this composite body 7 is smaller than the thickness of the original mat 4. Depending on the particular application, it may be desirable to vary the mixing ratio glass / PP in the composite body from case to case, starting from fiber strands 3 which always have the same ratio of Have glass to PP, for example 60:40, which obviously simplifies storage, ie it is not necessary to store different fiber strands with different glass / PP ratios in a manufacturing plant. If the end product has to have a higher proportion of glass fibers, in addition to the “standard” fiber strands 3 and together with the same glass rovings, glass fibers are placed on a respective base and processed into a mat 4. The processing can be done by means of needles or cohesive connection techniques. Such a mat 4, which is needled as an example, is shown in FIG. 4. It therefore has fiber strands 3 made of glass and PP fibers and additionally fibers 10 made of glass, that is glass fibers.
Sollte umgekehrt der Anteil an PP höher als in den Fasersträngen 3 ab Lager sein, bestehen die zusätzlichen Fasern 10 aus PP. Offensichtlich ist es auch möglich, den Fasersträngen 3 zusätzlich sowohl zusätzliche Fasern aus Glas und zusätzliche Fasern aus PP zuzugeben.Conversely, if the proportion of PP is higher than in the fiber strands 3 from stock, the additional fibers 10 consist of PP. Obviously, it is also possible to add both additional fibers made of glass and additional fibers made of PP to the fiber strands 3.
Vorteilhaft werden die Glasfasern in Form von bekannten Glasrovings und die PP-Fasern in Form von Mul- tifilamenten abgelegt.The glass fibers are advantageously deposited in the form of known glass rovings and the PP fibers in the form of multifilaments.
Als weitere Variante kann zusätzliches Polypropylen der Matte 4 erst unmittelbar vor dem Eintritt in die Doppelbandpresse zugegeben werden. Diese Variante ist in der Fig. 8 gezeichnet. Unmittelbar vor dem Eintritt in die Doppelbandpresse 5 wird zusätzliches Polypropylen in Form einer (oder mehreren) Folienbahn (en) 15 zugeführt, oder auch in Form (mindestens) eines Schmelztilmes . Beim Vernadeln werden bekanntlich vorwiegend die etwas spröden Glasfasern zerbrochen, d.h. verkürzt. Für verschiedene Anwendungen sind jedoch zu gross Anteile von verkürzten Glasfasern, die vorwiegend als Bewehrung im Endprodukt dienen, unerwünscht. Daher sollte das Vernadeln auf ein Minimum reduziert werden. Jedoch muss die Matte, die letztlich zu einem Verbundkörper verarbeitet werden soll, nach wie vor gehandhabt werden können und transportfähig sein. Dazu werden gemäss einer weiteren Ausführung der Erfindung die Faserstränge 3 auf ein Wirrvlies 13 (in der Fachsprache auch Nonwoven genannt) aus PP abgelegt (also nicht untereinander vernadelt) und nur mit der für das Nachfolgende Handling notwendigen minimalen Anzahl Nadelstichen auf dem Wirrvlies 13 fixiert, wie in der Fig. 5 gezeichnet ist.As a further variant, additional polypropylene can be added to the mat 4 only immediately before it enters the double belt press. This variant is drawn in FIG. 8. Immediately before entering the double belt press 5, additional polypropylene is fed in the form of one (or more) film web (s) 15, or also in the form of (at least) a melt film. It is known that when needling, the somewhat brittle glass fibers are mainly broken, ie shortened. For various applications, too large proportions of shortened glass fibers, which mainly serve as reinforcement in the end product, are undesirable. Needling should therefore be reduced to a minimum. However, the mat that is ultimately to be processed into a composite body must still be able to be handled and be transportable. For this purpose, according to a further embodiment of the invention, the fiber strands 3 are placed on a tangled nonwoven 13 (also called nonwoven in technical terminology) made of PP (that is, not needled to one another) and only fixed on the tangled nonwoven 13 with the minimum number of needle sticks required for the subsequent handling, as drawn in FIG. 5.
Anstelle des Wirrvlieses kann gemäss der in Fig. 6 gezeigten Ausführung eine dünne PP-Folienbahn 14, ein PP-Film verwendet werden. Auch bei dieser Ausführung erfolgt die Verbindung zwischen den Fasersträngen 3 und der Folienbahn 14 mittels einem minimalen Vernadeln.Instead of the tangled nonwoven, a thin PP film web 14, a PP film, can be used according to the embodiment shown in FIG. 6. In this embodiment, too, the connection between the fiber strands 3 and the film web 14 takes place by means of minimal needling.
Alternativ kann das Wirrvlies 13 auch aus Glasfasern, also dem ersten Material bestehen.Alternatively, the random fleece 13 can also consist of glass fibers, that is to say the first material.
Der Verbundkörper 7 lässt sich nun zu endgültigen Bauteilen, z.B. für Strassenfahrzeuge, umformen. Es wird auf die Fig. 9 verwiesen.The composite body 7 can now be made into final components, e.g. for road vehicles. Reference is made to FIG. 9.
Es werden aus dem Verbundkörper 7 dem jeweils herzustellenden Bauteil entsprechende Zuschnitte 9 hergestellt. Abhängig von der nachfolgenden Verarbeitung wird nur ein einzelner Zuschnitt 9 oder werden mehrere Zu- schnitte zusammen in Form eines Rohlinggebildes verwendet. Das aus einem Zuschnitt 9 oder mehreren Zuschnitten bestehende Rohlinggebilde entspricht dabei gewichtsmässig dem Fertigteilgewicht des herzustellenden Bauteils.Blanks 9 corresponding to the component to be manufactured are produced from the composite body 7. Depending on the subsequent processing, only a single blank 9 or multiple blanks are used together in the form of a blank structure. The blank structure consisting of a blank 9 or more blanks corresponds in weight to the weight of the finished part of the component to be manufactured.
Die Zuschnitte 9 werden in bekannter Weise im Durchlauf in Heizgeräten, z.B. Infrarotöfen nochmals erwärmt, so dass die thermoplastische Komponente des Rohlinggebildes aus einem oder mehreren Zuschnitten 9 wieder fliessfähig wird. Danach wird ein jeweiliges aufgeheiztes Rohlinggebilde, bzw. Zuschnitt 9 in ein Formwerkzeug, das z.B. eine Matrize 11 und eine Patrize 12 aufweist, eingelegt und das Formwerkzeug geschlossen, wie mit dem Pfeil B angedeutet ist. Im Formwerkzeug wird das Rohlinggebilde unter Druck verpresst und danach abgekühlt, so dass schlussendlich der herzustellende Bauteil geformt ist. The blanks 9 are reheated in a known manner in a continuous manner in heaters, for example infrared ovens, so that the thermoplastic component of the blank structure from one or more blanks 9 again becomes flowable. Then a respective heated blank structure or blank 9 is inserted into a molding tool, which has, for example, a female mold 11 and a male mold 12, and the molding tool is closed, as indicated by the arrow B. The blank is pressed under pressure in the molding tool and then cooled, so that the component to be produced is finally shaped.

Claims

Patentansprüche claims
1. Matte, die Fasern aus unterschiedlichen Materialien aufweist, dadurch gekennzeichnet, dass mindestens ein Teil der Fasern in Form von Fasersträngen vorliegt, wobei jeder Faserstrang (3) eine Vielzahl erste Fasern (1) aus einem ersten Material und eine Vielzahl zweite Fasern (2) aus einem zweiten, vom ersten verschie- denen Material enthält, dass in jedem Faserstrang (3) die ersten Fasern (1) mit den zweiten Fasern (2) unverbunden und zu denselben gleitend angeordnet sind, und dass die Faserstränge (3) durch eine formschlüssige Verbindung derselben und/oder eine stoffschlüssige Verbindung der ersten und/oder der zweiten Fasern (2) zusammengehalten sind.1. Mat, which has fibers made of different materials, characterized in that at least some of the fibers are in the form of fiber strands, each fiber strand (3) having a plurality of first fibers (1) made of a first material and a plurality of second fibers (2 ) made of a second material, different from the first, contains in each fiber strand (3) the first fibers (1) with the second fibers (2) unconnected and slidably arranged, and that the fiber strands (3) by a positive connection of the same and / or a material connection of the first and / or the second fibers (2) are held together.
2. Matte nach Anspruch 1, dadurch gekennzeichnet, dass die Faserstränge (3) in Form eines Wirrvlieses im formschlüssigen Zustand miteinander vernadelt und im stoffschlüssigen Zustand durch ein chemisches der ersten (1) oder ein thermisches Bonding der zweiten Fasern (2) untereinander zusammengehalten sind.2. Mat according to claim 1, characterized in that the fiber strands (3) are needled in the form of a tangled nonwoven in the form-fitting state and are held together in the material-fitting state by chemical bonding of the first (1) or thermal bonding of the second fibers (2) .
3. Matte nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass ein weiterer Teil der Fasern in Form von Einzelfasern (10) aus dem ersten und/oder dem zweiten Material vorliegt, welche Fasern (10) formschlüssig mit den Fasersträngen (3) und/oder stoffschlüssig mit mindestens einem Teil deren Fasern (1; 2) verbunden sind.3. Mat according to claim 1 or 2, characterized in that a further part of the fibers is in the form of individual fibers (10) made of the first and / or the second material, which fibers (10) form-fitting with the fiber strands (3) and / or cohesively connected to at least part of their fibers (1; 2).
4. Matte nach einem der Ansprüche 1 oder 3, gekennzeichnet durch mindestens eine an mindestens einer4. Mat according to one of claims 1 or 3, characterized by at least one to at least one
Hauptseite derselben angeordneten Trägerschicht (13; 14) aus dem zweiten Material, welche Trägerschicht (13; 14) mit dem restlichen Teil der Matte vernadelt ist.Main side of the same arranged carrier layer (13; 14) made of the second material, which carrier layer (13; 14) is needled to the rest of the mat.
5. Matte nach einem Anspruch 4, dadurch ge- kennzeichnet, dass die Trägerschicht (13; 14) als Wirrvlies (13) oder Folienbahn aus dem zweiten Material ausgebildet ist. 5. Mat according to claim 4, characterized in that the carrier layer (13; 14) is formed as a random fleece (13) or film web made of the second material.
6. Matte nach Anspruch 4, dadurch gekennzeichnet, dass die Trägerschicht als Wirrvlies (13) aus dem ersten Material ausgebildet ist.6. Mat according to claim 4, characterized in that the carrier layer is formed as a random fleece (13) from the first material.
7. Matte nach Anspruch 1, dadurch gekenn- zeichnet, dass der Schmelzpunkt des ersten Materials höher als der Schmelzpunkt des zweiten Materials ist.7. Mat according to claim 1, characterized in that the melting point of the first material is higher than the melting point of the second material.
8. Matte nach Anspruch 1 , dadurch gekennzeichnet, dass das erste Material Glas und das zweite Material ein thermoplastischer Kunststoff ist. 8. Mat according to claim 1, characterized in that the first material is glass and the second material is a thermoplastic.
9. Matte nach Anspruch 1, dadurch gekennzeichnet, dass das zweite Material Polypropylen ist.9. Mat according to claim 1, characterized in that the second material is polypropylene.
10. Verfahren zur Herstellung der Matte nach Anspruch 1, dadurch gekennzeichnet, dass die Faserstränge (3) in Form von endlosen oder geschnittenen Fasersträngen auf eine ebenflächige Unterlage abgelegt werden, und danach durch ein Vernadeln der Faserstränge (3) zu einem Wirrvlies, oder durch ein chemisches oder thermisches Bonding des ersten und/oder zweiten Materials die Faserstränge zu einer Matte verfestigt werden. 10. The method for producing the mat according to claim 1, characterized in that the fiber strands (3) are deposited in the form of endless or cut fiber strands on a flat surface, and then by needling the fiber strands (3) to a random fleece, or by a chemical or thermal bonding of the first and / or second material, the fiber strands are consolidated into a mat.
11. Verfahren nach Anspruch 10, wobei zusätzlich zu den Fasersträngen (3) Fasern (10) in Form von Einzelfasern aus dem ersten und/oder zweiten Material vorliegen, dadurch gekennzeichnet, dass die als Einzelfasern vorliegenden Fasern (10) zusammen mit den Faser- strängen (3) abgelegt und zu einem Wirrvlies, bzw. einer Matte verfestigt werden.11. The method according to claim 10, wherein, in addition to the fiber strands (3), fibers (10) are present in the form of individual fibers made of the first and / or second material, characterized in that the fibers (10) present as individual fibers together with the fiber strands (3) are deposited and solidified into a tangled fleece or mat.
12. Verfahren zur Herstellung der Matte nach Anspruch 4, dadurch gekennzeichnet, dass die Faserstränge12. The method for producing the mat according to claim 4, characterized in that the fiber strands
(3) auf die die Trägerschicht bildende Folienbahn (14) oder Wirrvlies (13) abgelegt und danach mit der Folienbahn (14) oder dem Wirrvlies (13) vernadelt werden.(3) placed on the film web (14) or random fleece (13) forming the carrier layer and then needled with the film web (14) or the random fleece (13).
13. Verfahren nach Anspruch 10, bei welchem ein weiterer Teil der Fasern (10) in Form von Einzelfasern aus Glas vorliegt, dadurch gekennzeichnet, dass diese Fasern (10) in Form von Glasrovings zusammen mit den Fasersträngen (3) abgelegt und vernadelt werden. 13. The method according to claim 10, in which a further part of the fibers (10) is in the form of individual fibers made of glass, characterized in that these fibers (10) are deposited and needled in the form of glass rovings together with the fiber strands (3).
14. Verfahren nach Anspruch 10, bei welchem ein weiterer Teil der Fasern (10) in Form von Einzelfasern aus einem thermoplastischen Kunststoff vorliegt, dadurch gekennzeichnet, dass diese Fasern (10) in Form von Multifilamenten zusammen mit den Fasersträngen (3) abgelegt und vernadelt werden.14. The method according to claim 10, in which a further part of the fibers (10) is in the form of individual fibers made of a thermoplastic, characterized in that these fibers (10) are deposited and needled in the form of multifilaments together with the fiber strands (3) become.
15. Thermisch verformbarer Verbundkörper, hergestellt aus einer oder mehreren Matten (4) nach einem der Ansprüche 1-8, dadurch gekennzeichnet, dass alle Fa- sern (1) aus dem ersten Material in einem wirr angeordneten Zustand in dem von den Fasern aus dem zweiten Material stammenden Material (8) eingebettet sind, welches Material (8) in einem einstückigen Zustand im Verbundkörper (7) homogen verteilt ist. 15. A thermally deformable composite body, made from one or more mats (4) according to any one of claims 1-8, characterized in that all fibers (1) made of the first material in a tangled state in that of the fibers from the second material (8) are embedded, which material (8) is homogeneously distributed in a one-piece state in the composite body (7).
16. Verfahren zur Herstellung des thermisch verformbaren Verbundkörpers nach Anspruch 15, bei welchem das zweite Material ein thermoplastischer Kunststoff ist, dadurch gekennzeichnet, dass eine Matte nach einem der Ansprüche 1-8 in einem kontinuierlichen Vorgang in einem ersten Schritt erwärmt wird um den thermoplastischen16. A method for producing the thermally deformable composite body according to claim 15, wherein the second material is a thermoplastic, characterized in that a mat according to one of claims 1-8 is heated in a continuous process in a first step around the thermoplastic
Kunststoff aufzuschmelzen und einem Druck ausgesetzt wird um eine homogene Durchdringung aller Fasern aus dem ersten Material (1) durch den schmelzflüssigen Kunststoff zu erreichen, und in einem zweiten Schritt abgekühlt wird, so dass eine Verfestigung zu einem kompakten Verbundkörper (7) erfolgt, oder dass vorerst mehrere Matten (4) schichtweise aufeinander gelegt und danach nach dem ersten und zweiten Schritt behandelt werden.Melt plastic and is subjected to pressure to achieve a homogeneous penetration of all fibers from the first material (1) through the molten plastic, and is cooled in a second step, so that solidification takes place to form a compact composite body (7), or that for the time being, several mats (4) are placed on top of each other in layers and then treated after the first and second step.
17. Verfahren nach Anspruch 16, dadurch ge- kennzeichnet, dass einer jeweiligen Matte (4) vor dem Erwärmen mindestens eine Folienbahn (15) oder ein Schmelzfilm aus dem zweiten Material zugeführt wird und danach der damit gebildete Schichtkörper in dem kontinuierlichen Vorgang unter Ausübung von Druck erwärmt und danach abge- kühlt wird um einen kompakten Verbundkörper (7) zu bilden. 17. The method according to claim 16, characterized in that at least one film web (15) or a melt film made of the second material is fed to a respective mat (4) before heating and then the layered body formed therewith in the continuous process while exercising Pressure is heated and then cooled to form a compact composite body (7).
18. Verfahren zur Herstellung eines Bauteils aus einem thermisch verformbaren Verbundkörper (7) nach Anspruch 15, welcher Bauteil ein vorgegebenes Gewicht aufweist, dadurch gekennzeichnet, dass aus dem Verbund- körper ein Rohlinggebilde (9) aus einem oder mehreren zusammengenommenen Zuschnitten hergestellt wird, dessen Gewicht dem vorgegebenen Gewicht des Bauteils entspricht, dass das einen oder mehrere Zuschnitte enthaltende Rohlinggebilde in ein mindestens eine Patrize (11) und min- destens eine Matrize (12) aufweisendes Formwerkzeug eingebracht wird und im Formwerkzeug unter Druck verpresst und danach abgekühlt wird, und danach der somit hergestellte Bauteil aus dem Formwerkzeug entnommen wird.18. A method for producing a component from a thermally deformable composite body (7) according to claim 15, which component has a predetermined weight, characterized in that a blank structure (9) is produced from the composite body from one or more combined blanks, the Weight corresponds to the predetermined weight of the component such that the blank structure containing one or more blanks is introduced into a mold having at least one male (11) and at least one female mold (12) and is pressed under pressure in the mold and then cooled, and then the component thus produced is removed from the mold.
19. Bauteil, hergestellt nach dem Verfahren nach Anspruch 18, dadurch gekennzeichnet, dass er in einer Matrix aus einem Kunststoff wirr angeordnet verteilte Fasern aufweist. 19. Component, produced by the method according to claim 18, characterized in that it has fibers arranged in a tangled arrangement in a matrix made of a plastic.
PCT/IB1997/000078 1997-02-05 1997-02-05 Mat made of fibres of different materials, composite body produced therewith and process for producing parts made of such composite bodies WO1998035086A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP97900719A EP0958420A1 (en) 1997-02-05 1997-02-05 Mat made of fibres of different materials, composite body produced therewith and process for producing parts made of such composite bodies
PCT/IB1997/000078 WO1998035086A1 (en) 1997-02-05 1997-02-05 Mat made of fibres of different materials, composite body produced therewith and process for producing parts made of such composite bodies

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IB1997/000078 WO1998035086A1 (en) 1997-02-05 1997-02-05 Mat made of fibres of different materials, composite body produced therewith and process for producing parts made of such composite bodies

Publications (1)

Publication Number Publication Date
WO1998035086A1 true WO1998035086A1 (en) 1998-08-13

Family

ID=11004524

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB1997/000078 WO1998035086A1 (en) 1997-02-05 1997-02-05 Mat made of fibres of different materials, composite body produced therewith and process for producing parts made of such composite bodies

Country Status (2)

Country Link
EP (1) EP0958420A1 (en)
WO (1) WO1998035086A1 (en)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002062563A1 (en) * 2001-02-08 2002-08-15 Quadrant Plastic Composites Ag Method for producing a thermoplastically deformable, fibre-reinforced semi-finished product
WO2002076711A1 (en) * 2001-03-24 2002-10-03 Quadrant Plastic Composites Ag Method of producing a thick, thermoformable, fiber-reinforced semi-finished product
WO2003038175A1 (en) * 2001-10-17 2003-05-08 Saertex Wagener Gmbh & Co. Kg Textile reinforcement comprising at least one cover layer and one voluminous nonwoven layer
WO2008139423A1 (en) * 2007-05-15 2008-11-20 Gilbert Chomarat Reinforcement textile armature and method for making same
WO2011021133A1 (en) * 2009-08-21 2011-02-24 Gilbert Chomarat Textile core having continuous glass fibers
US8540830B2 (en) 2003-10-24 2013-09-24 Quadrant Plastic Composites, AG Method of producing a thermoplastically moldable fiber-reinforced semifinished product
EP3039060A1 (en) * 2013-08-30 2016-07-06 Continental Structural Plastics, Inc. Overmolding with non-oriented fibers

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3242033A (en) * 1962-02-21 1966-03-22 Fiber Glass Ind Inc Glass fiber mat
US3623935A (en) * 1965-12-28 1971-11-30 Celanese Corp Fluid-entangled nonwoven fabric
US3920879A (en) * 1971-11-01 1975-11-18 Allied Chem Glass fiber filled polyamide composites
EP0296970A1 (en) * 1987-06-26 1988-12-28 Vetrotex Saint-Gobain Method and apparatus for needling a glassfibre mat and composite article made from this mat
EP0417827A1 (en) * 1989-08-31 1991-03-20 Dsm N.V. Fabric of thermoplastic fibre and continuous reinforcing fibre
EP0465917A1 (en) * 1990-07-02 1992-01-15 Ppg Industries, Inc. Method and apparatus for manufacturing continuous fiber glass strand reinforcing mat
WO1995012701A1 (en) * 1993-11-05 1995-05-11 Owens Corning Dual-glass fiber insulation product

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3242033A (en) * 1962-02-21 1966-03-22 Fiber Glass Ind Inc Glass fiber mat
US3623935A (en) * 1965-12-28 1971-11-30 Celanese Corp Fluid-entangled nonwoven fabric
US3920879A (en) * 1971-11-01 1975-11-18 Allied Chem Glass fiber filled polyamide composites
EP0296970A1 (en) * 1987-06-26 1988-12-28 Vetrotex Saint-Gobain Method and apparatus for needling a glassfibre mat and composite article made from this mat
EP0417827A1 (en) * 1989-08-31 1991-03-20 Dsm N.V. Fabric of thermoplastic fibre and continuous reinforcing fibre
EP0465917A1 (en) * 1990-07-02 1992-01-15 Ppg Industries, Inc. Method and apparatus for manufacturing continuous fiber glass strand reinforcing mat
WO1995012701A1 (en) * 1993-11-05 1995-05-11 Owens Corning Dual-glass fiber insulation product

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002062563A1 (en) * 2001-02-08 2002-08-15 Quadrant Plastic Composites Ag Method for producing a thermoplastically deformable, fibre-reinforced semi-finished product
WO2002076711A1 (en) * 2001-03-24 2002-10-03 Quadrant Plastic Composites Ag Method of producing a thick, thermoformable, fiber-reinforced semi-finished product
US7132025B2 (en) 2001-03-24 2006-11-07 Quadrant Plastic Composites Ag Method of producing a thick, thermoformable, fiber-reinforced semi-finished product
WO2003038175A1 (en) * 2001-10-17 2003-05-08 Saertex Wagener Gmbh & Co. Kg Textile reinforcement comprising at least one cover layer and one voluminous nonwoven layer
US8540830B2 (en) 2003-10-24 2013-09-24 Quadrant Plastic Composites, AG Method of producing a thermoplastically moldable fiber-reinforced semifinished product
WO2008139423A1 (en) * 2007-05-15 2008-11-20 Gilbert Chomarat Reinforcement textile armature and method for making same
FR2916209A1 (en) * 2007-05-15 2008-11-21 Gilbert Chomarat TEXTILE REINFORCING REINFORCEMENT AND METHOD OF MAKING SAME
US20110151231A1 (en) * 2007-05-15 2011-06-23 Gilbert Chomarat Reinforcement textile armature and method for making same
CN101680144B (en) * 2007-05-15 2013-01-23 吉尔伯特·肖马拉 Reinforced fabric framework and manufacturing method thereof
FR2916208A1 (en) * 2007-05-15 2008-11-21 Gilbert Chomarat TEXTILE REINFORCING REINFORCEMENT AND METHOD FOR MAKING THE SAME.
WO2011021133A1 (en) * 2009-08-21 2011-02-24 Gilbert Chomarat Textile core having continuous glass fibers
FR2949238A1 (en) * 2009-08-21 2011-02-25 Gilbert Chomarat TEXTILE ARMATURE WITH CONTINUOUS GLASS THREADS
CN102482820A (en) * 2009-08-21 2012-05-30 吉尔伯特·肖马拉 Fabric core with continuous glass fibers
EP3039060A1 (en) * 2013-08-30 2016-07-06 Continental Structural Plastics, Inc. Overmolding with non-oriented fibers
EP3039060A4 (en) * 2013-08-30 2017-04-26 Continental Structural Plastics, Inc. Overmolding with non-oriented fibers
US9718932B2 (en) 2013-08-30 2017-08-01 Continental Structural Plastics, Inc. Overmolding with non-oriented fibers

Also Published As

Publication number Publication date
EP0958420A1 (en) 1999-11-24

Similar Documents

Publication Publication Date Title
EP1060069B1 (en) Fibrous structure arrangement and a method for producing a preform
EP0657281B1 (en) Laminated building element
EP0542186B1 (en) Method for manufacturing of multilayered material from recycled plastics, and multilayered material containing recycled plastics
EP2797729B1 (en) Method and device for producing a fibre composite material in the form of at least one wide fibre strip impregnated with a polymer
EP2903794B1 (en) Method for manufacturing a semi-finished product for producing a composite moulded part
EP2846986B1 (en) Method for consolidating a perform at least in some regions in order to produce a molded part in a mold
WO1993024695A1 (en) Flat structure containing a foil-like material and process for manufacturing the same
EP0956193B1 (en) Thermoplastically deformable composite body
EP2737987B1 (en) Method and device for producing an internal trim lining
EP2447401B1 (en) Partially fixed textile semi finished product
WO1998035086A1 (en) Mat made of fibres of different materials, composite body produced therewith and process for producing parts made of such composite bodies
DE102015012537B3 (en) Process for producing continuous fiber-reinforced plastics and a corresponding device
EP3463825B1 (en) Method for producing a component from a fibre-composite material
EP3877171B1 (en) Method for producing a thermoplastically deformable fibre-reinforced flat semi-finished product
DE4412376C2 (en) Workpiece
EP2762295A1 (en) Method and semi-finished product for producing a fibre reinforced moulded part and fibre reinforced moulded part
DE102013218143A1 (en) Reinforced semi-finished fiber product and process for its production
DE102004009245B4 (en) Method for producing a plastic molded part consisting of a nonwoven layer partly penetrated by a plastic material in the direction of the layer thickness
WO2000000351A1 (en) Method for producing a composite body from fibre-reinforced plastic and composite body produced according to this method
DE202005003045U1 (en) Processing aid for the resin injection process
EP0400766B1 (en) Method for producing fibre mats containing a binding agent
DE102007028872A1 (en) Laminar composite structure component manufacturing method, involves merging polymer melt-paths in warmth with band-like and laminar structure, and pressing sandwich structure in warmth to end product forming laminar structure component
EP3310571A1 (en) Composite component for a vehicle, particularly a motor vehicle, and a method for producing a composite component
EP3680097A1 (en) Method for producing a thermoplastically deformable fibre-reinforced flat semi-finished product
DE102014119529A1 (en) Process for the production of fiber-reinforced semi-finished products

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A1

Designated state(s): BR JP KR US

AL Designated countries for regional patents

Kind code of ref document: A1

Designated state(s): AT BE CH DE DK ES FI FR GB GR IE IT LU MC NL PT SE

DFPE Request for preliminary examination filed prior to expiration of 19th month from priority date (pct application filed before 20040101)
121 Ep: the epo has been informed by wipo that ep was designated in this application
WWE Wipo information: entry into national phase

Ref document number: 1997900719

Country of ref document: EP

NENP Non-entry into the national phase

Ref country code: CA

WWP Wipo information: published in national office

Ref document number: 1997900719

Country of ref document: EP

NENP Non-entry into the national phase

Ref country code: JP

Ref document number: 1998534025

Format of ref document f/p: F

WWR Wipo information: refused in national office

Ref document number: 1997900719

Country of ref document: EP

WWW Wipo information: withdrawn in national office

Ref document number: 1997900719

Country of ref document: EP