Short title. Laminate of metal layers whicn are connected by a flber-remforceα adhesive
The invention relates to a laminate comprising a large number of metal layers which are connected to one another cy an adhesive layer, which adhesive layer is reinforced by a cohesive structure comprising groups of fibres which are substantially parallel to one another, the direction of the fibres differing from group to group and there being two or more different, distinguishable directions of fibres
A laminate of this nature is known from EP-A-0 , 056 , 289. The abovementioned publication describes a laminate of the type indicated m which metal layers, such as for example layers of aluminium or an aluminium alloy, are connected to one another with the aid of an adhesive layer m which the fibres used are, for example, polyparaphenylene terephthalamide fibres, and the fibres can be formed into a woven fabric or a structure containing fibres running m two or more directions.
The abovementioned laminate is formed in such a manner that it can satisfy the high demands which are imposed m the aeronautical sector and in the construction of spacecraft, in particular with regard to weight and mechanical properties. Although the laminates of the type described are eminently satisfactory for tne purposes indicated and have good properties, further improvement is desired, and m particular there is an ongoing demand for a material which has the highest possible fatigue strength. The applicant has carried out research on such materials and, surprisingly, has found that a laminate of the type indicated can create a better fatigue strength if, according to the invention, the cohesive structure of fibres comprises a plurality of layers, and each layer forms a group, and the fibres of a layer always cross the fibres of another layer, while the fibres of one layer, at the crossing points, are connected to the fibres of another layer with the aid of connecting fibres.
It is assumed that m particular the presence of the connecting fibres is of benefit to the reinforcing action of the
cohesive structure, with the result that the fatigue strength of the metal laminate is substantially improved.
With regard to the metal layers which are used, it can in general terms be said that their thickness is often from 0.25 to 1.0 mm; they are made from aluminium or an aluminium alloy, for example an aluminium-copper or aluminium- zinc alloy, while the percentage of threads in the adhesive layer may be from 30 to 60, preferably 45 to 60, % by weight, calculated on the total weight of adhesive plus threads. In particular, the cohesive structure comprises four layers of fibres, while the direction of the fibres of a first layer and the direction of the fibres of the other three layers form angles of 45, 90 and 135 degrees with one another.
With regard to the connection of the fibres at their crossing points, it can be stated that the layers are preferably connected by stitching with the aid of the connecting fibres at the crossing points of the fibres.
The stitching preferably takes place at crossing points with the highest possible density, i.e. crossing points at which three threads cross one another are preferred to crossing points at which two threads cross one another.
In an attractive embodiment of the laminate according to the invention, the cohesive structure comprises at least a first partial fibre structure and a second partial fibre structure, which can be distinguished from one another, each of the partial fibre structures having a design similar to the cohesive structure of the laminate as described above, which partial fibre structures bear against one another in a bearing plane, the partial fibre structures likewise being connected to one another with the aid of connecting fibres.
This cohesive structure composed of two or more partial fibre structures is attractive since a cohesive structure comprising, for example, four layers can be formed successfully on existing equipment, whereas a structure comprising more layers, while not impossible, is complicated and labour-intensive. Forming the cohesive structure in the laminate from two or more partial fibre structures which are connected to one another with the aid of connecting fibres makes it possible to form cohesive structures which are built up from partial fibre structures and
in which the overall structure may comprise a desired number of layers .
In a highly attractive embodiment, it is ensured, in the laminate according to the invention, that the crossing points of the fibres of the first and second partial fibre structures of a cohesive fibre structure comprising two partial fibre structures coincide when projected at right angles on to the bearing plate.
In an even more attractive embodiment, it is ensured, in the laminate, that the layers of the first and second partial fibres structures are arranged mirror-symmetrically with respect to the bearing surface.
A symmetrically designed, cohesive structure of fibres of this nature has proven to provide extremely good results, the laminate having an almost isotropic character which coincides with the almost isotropic character of the cohesive structure of fibres which is composed of plurality of partial fibre structures .
Moreover, it should be noted that the use of the cohesive structure of fibres as described above but in which the cohesive structure is not composed of partial fibre structures, also exhibit excellent strength properties which are attributable to the strongly almost isotropic character of the single cohesive structure which is used according to the invention and in which fibres are arranged in layers, it is possible to distinguish between two or more fibre directions and in which the fibres are connected at the crossing points with the aid of connecting fibres.
With regard to the fibres which are to be used in the laminate according to the invention, it will be clear that numerous types of fibres can be used, such as Aramide fibres and other suitable fibres; good results are obtained with glass fibres and polyester fibres; however, the invention is not limited to the use of the abovementioned fibres.
With regard to the characteristics of the fibres to be used, it should be noted that the person skilled in the art will know how to select the weight of these fibres in connection with the desired properties of the laminate; in general, fibres with a weight of from 1500 to 5000 denier will be selected for the
O 00/53408 - 4 - PCT/NLOO/00160 fibres which form the cohesive structure, while the weight of the connecting fibres may be from 20 to 100 denier.
In a typical example, polyester or glass fibres with a weight of 3600 denier are used, while connecting fibres of this nature which have a weight of 72 denier are used.
The person skilled in the art will also be able to select the appropriate adhesive on the basis of his knowledge and experience. Adheεives which are frequently used are thermosetting systems, for example based on epoxy resin, phenolic resin, polyimide resin, etc.
The invention will now be described with reference to the drawing, in which:
Figs. 1A and IB diagrammatically depict a plan view and a side view, respectively, of a partial fibre structure which is composed of four layers of fibres.
Fig. 2 diagrammatically depicts a fibre structure composed of two partial fibre structures;
Fig. 3 diagrammatically depicts the arrangement of the layers of two partial fibre structures which are connected to one another, in a preferred embodiment; and
Fig. 4 diagrammatically depicts a laminate according to the invention comprising four metal layers.
In Figs. 1A and IB, the fibres are denoted by 1, 2, 3 and 4, of which, for example, fibres 4 are parallel to the longitudinal direction of the cohesive fibre structure, which in this case is in the form of a web; the fibres 3 are perpendicular thereto, and the fibres 1 and 2 form angles of +45 and -45 degrees, respectively, with the longitudinal direction of the cohesive fibre structure. 5 Denotes connecting threads which have been processed into a stitched fabric which, at the location of the crossing points with the highest density, surrounds the entire stack of fibres (cf. Fig. IB).
The stitching does not involve penetration through the fibres, so that they retain their original strength. Fig. 2 diagrammatically depicts an assembly of a first partial fibre structure 21 and a second partial fibre structure 22, with a bearing surface 23. Both partial fibre structures are composed of four fibre layers, as diagrammatically indicated; to produce the web-like fibre structure, firstly the partial fibre
structure 21 is produced in a machine which is known per se, after which the partial fibre structure 21 which has been formed in this way is introduced into the machine once again in order to form the partial fibre structure 22 which is connected to the partial fibre structure 21. The partial fibre structures bear against one another in the bearing surface 23.
Fig. 3 diagrammatically depicts the arrangement of the various layers for a cohesive fibre structure in a preferred embodiment. The first partial fibre structure comprises fibre layers 31, 32, 33 and 34 which, in a manner known per se, are connected to one another by means of vertical connections between the layers. The partial fibre structure formed in this way is reintroduced into the machine, and then the second partial fibre structure is formed on the first partial fibre structure, the layers 31', 32', 33' and 34' being arranged mirror- symmetrically with respect to the layers of the first partial fibre structure, and the bearing surface 35 functioning as a plane of symmetry.
Fig. 4 diagrammatically depicts a metal laminate according to the invention which comprises aluminium layers 40, 41, 42 and 43, which layers are connected by adhesive layers 44, 45 and 46 which, according to the invention, are reinforced with a cohesive structure of fibres 47, 48 and 49.
The aluminium plate used for the layers 40, 41, 42 and 43 was Pretreated Aluminium type 2024.
The layers 44, 45 and 46 are, for example, hardened synthetic resin layers reinforced with glass fibres, the resin system comprising a modified epoxy resin such as for example AF 153® produced by 3M Company and FN94® produced by Cytec . The glass fibre reinforcement is, for example, a fibre structure such as that shown in Fig. 1, with the following parameters:
Fibre Direction Fibre tex Material
1 +45° 400 tex S2 glass fibre
2 -45° 400 tex S2 glass fibre
3 +90° 400 tex S2 glass fibre
4 0° 400 tex S2 glass fibre
5 - 80 dtex Polyester