WO2014105437A1 - Matériaux de moulage thermoplastiques à basse pression pour structures composites renforcées de fibres - Google Patents

Matériaux de moulage thermoplastiques à basse pression pour structures composites renforcées de fibres Download PDF

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Publication number
WO2014105437A1
WO2014105437A1 PCT/US2013/074561 US2013074561W WO2014105437A1 WO 2014105437 A1 WO2014105437 A1 WO 2014105437A1 US 2013074561 W US2013074561 W US 2013074561W WO 2014105437 A1 WO2014105437 A1 WO 2014105437A1
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WO
WIPO (PCT)
Prior art keywords
fiber
reinforced
tape
discontinuous
strips
Prior art date
Application number
PCT/US2013/074561
Other languages
English (en)
Inventor
Joel A. Dyksterhouse
Original Assignee
Thercom Holdings, Llc
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 Thercom Holdings, Llc filed Critical Thercom Holdings, Llc
Publication of WO2014105437A1 publication Critical patent/WO2014105437A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/587—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads adhesive; fusible
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • 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
    • B32B5/024—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
    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D23/00—General weaving methods not special to the production of any particular woven fabric or the use of any particular loom; Weaves not provided for in any other single group
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D3/00—Woven fabrics characterised by their shape
    • D03D3/005—Tapes or ribbons not otherwise provided for
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • 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
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B32B2307/734—Dimensional stability
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/249942—Fibers are aligned substantially parallel
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/249942—Fibers are aligned substantially parallel
    • Y10T428/249945—Carbon or carbonaceous fiber
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/249942—Fibers are aligned substantially parallel
    • Y10T428/249946—Glass fiber
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/249942—Fibers are aligned substantially parallel
    • Y10T428/249947—Polymeric fiber
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3033—Including a strip or ribbon
    • Y10T442/3041—Woven fabric comprises strips or ribbons only
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T83/00—Cutting
    • Y10T83/04—Processes
    • Y10T83/0405—With preparatory or simultaneous ancillary treatment of work
    • Y10T83/041—By heating or cooling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T83/00—Cutting
    • Y10T83/04—Processes
    • Y10T83/0481—Puncturing

Definitions

  • the present invention relates to fiber-reinforced thermoplastic molding materials for forming composite structures.
  • Fiber-reinforced molding materials are widely used in the manufacture of composite structures where high material strength and light weight are desired.
  • fiber-reinforced sheets are commonly used in the manufacture of automotive components, watercraft hulls, aircraft structures, piping, sporting equipment, and water tanks.
  • fiber-reinforced sheets include multiple fibers disposed in a matrix material that, when cured, form a lightweight and dimensionally stable structure adapted to withstand external loads.
  • Fiber-reinforced sheets generally include either continuous fiber strands or randomly oriented fiber segments.
  • Continuous fiber strands include unidirectional fibers, woven fibers and knitted fibers, and are primarily utilized in molding operations involving only a shallow draw. While the finished structure provides excellent strength and modulus, these molding materials are limited in their ability to be shaped into complex parts. That is, shaping sheet materials including continuous fiber strands into corners or cavities is a tenuous process with little high-production success, primarily attributed to the resistance of the continuous fiber strands to stretch or elongate.
  • Sheet materials including randomly oriented fiber segments exist primarily for the purpose of complex molding. Processes using these sheet materials include injection molding and compression molding. Both processes use sheet materials including relatively short fiber segments, often less than 1 inch, expensive tooling and high curing pressures. The molding processes can destroy and randomize fiber lengths, which ultimately affect the strength, modulus and dimensional stability of the completed part. Because extremely high pressures are used to quickly mold parts in a shortened cure cycle, fiber orientation is often destroyed and made unpredictable. This can lead to completed parts having poor dimensional stability, strength, and modulus.
  • Fiber-reinforced molding materials and a related method of manufacture are provided.
  • the fiber-reinforced molding materials include a fiber-reinforced tape having a plurality of discontinuous fiber segments extending unidirectionally within a thermoplastic matrix material.
  • the fiber-reinforced tape can be interwoven into multiple woven panels that are consolidated to form a fiber-reinforced mat.
  • the fiber-reinforced mat is moldable into complex structures at low pressures for a wide range of applications where high strength, good dimensional stability, and light weight are desired.
  • a method includes providing a fiber-reinforced tape including a plurality of unidirectional fibers disposed within a thermoplastic resin, and perforating the fiber-reinforced tape to separate the plurality of unidirectional fibers into a plurality of aligned discontinuous fiber segments.
  • This method can further include heating and pinch rolling the perforated tape to substantially close the perforations, and taking up the fiber-reinforced tape in a spool.
  • the taken-up fiber-reinforced tape includes a plurality of discontinuous fiber segments aligned in unidirectional columns extending lengthwise along the fiber-reinforced tape.
  • a method for forming a fiber-reinforced sheet includes providing a first plurality of fiber-reinforced weft strips, providing a first plurality of fiber-reinforced warp strips, and interweaving the warp strips and the weft strips to form a first woven panel, where the warp strips and the weft strips include a plurality of discontinuous fiber segments extending unidirectionally within a thermoplastic matrix material.
  • the method can further include layering a second woven panel over the first woven panel, the second woven panel including a second plurality of fiber-reinforced weft strips and a second plurality of fiber-reinforced warp strips, where the warp strips and the weft strips include a plurality of discontinuous fiber segments extending unidirectionally within a thermoplastic matrix material.
  • a method for molding a thermoplastic composite structure includes inserting a multi-layered woven mat into a compression mold having the exterior shape of the composite structure.
  • the multi- layered woven mat can include first and second woven panels each including a plurality of discontinuous fiber segments extending unidirectionally within a thermoplastic matrix material.
  • the method can additionally include closing the compression mold, applying heat and pressure to the multi-layered woven mat within the compression mold, and removing a cured composite structure from the compression mold.
  • Optional additional steps can include finishing the cured composite structure.
  • FIG. 1 is an illustration of a perforation process in accordance with an embodiment of the present invention.
  • Fig. 2 is an illustration of trimming and spooling processes in accordance with an embodiment of the present invention.
  • FIG. 3 is an illustration of a first perforation pattern.
  • FIG. 4 is an illustration of a second perforation pattern.
  • FIG. 5 is an illustration of a third perforation pattern.
  • FIG. 6 is an illustration of a fourth perforation pattern.
  • FIG. 7 is an illustration of a fifth perforation pattern.
  • Fig. 8 is an illustration of a weaving process in accordance with an embodiment of the present invention.
  • FIG. 9 is an illustration of a consolidation of multiple woven panels.
  • FIG. 10 is an illustration of a compression molding process in accordance with an embodiment of the present invention.
  • the invention as contemplated and disclosed herein includes a fiber- reinforced tape and a related method of manufacture.
  • the fiber-reinforced tape is moldable into complex structures at low pressures for a wide range of applications where high strength, dimensional stability, and light weight are desired.
  • the method generally includes providing a unidirectional tape 20 having continuous fibers within a thermoplastic resin.
  • the unidirectional tape 20 can be formed by introducing continuous dry reinforcing fibers into a molten resin, pulling the reinforcing fibers through an impregnation process to fully wet out the fibers and to spread the fibers into a desired dimension.
  • the molten tape is then cooled into a rigid tape while controlling the desired tape width and tape thickness.
  • the resulting tape includes a plurality of collimated bundles of fibers or 'tows' and having a desired fiber to resin ratio.
  • the fibers can include any fiber adapted to strengthen the unidirectional tape, including for example fiberglass, aramid, or carbon.
  • the resin can include a thermoplastic resin, including for example polyamide, polyethylene terephtalate, polyphenylene sulphide, polybutylene terephthalate, polysulfone, polycarbonate and combinations thereof.
  • the fibers are between about 20% and about 80% of the weight of the tape, further optionally between about 60% and about 65% by weight of the tape. Other fibers to resin ratios can also be used as desired, including concentrations within or outside of these ranges.
  • the continuous fibers are then separated into aligned discontinuous fiber segments in a perforation operation.
  • the perforation operation can be accomplished in-situ with the tape making process or as a separate procedure. As also shown in Fig.
  • the perforation operation includes drawing the unidirectional tape 20 through a perforator 22 to produce a specified and repeating pattern of slits or holes through the entire thickness of the tape 20.
  • the perforation operation can be accomplished by belt or roller tooling.
  • the tape is drawn through belt tooling at a rate of about 40 feet per minute to about 150 feet per minute.
  • roller speed is synchronized with the tape manufacturing line rate.
  • the perforation operation can produce a slit, producing no waste, or a punch, producing waste. Where the perforation operation produces a punch, the resulting waste can be collected by vacuum and held in storage.
  • the edges of the tape are generally not perforated, leaving an intact edge which is subsequently removed in a trimming operation as discussed below in connection with Fig. 2.
  • the perforator 22 includes an upper endless belt 24 and a lower endless belt 26 to draw the unidirectional tape 20 therethrough.
  • the upper endless belt 24 includes a plurality of teeth 28 in alignment with a plurality of recesses 30 in the lower endless belt 26.
  • Each belt 24, 26 is trained about a drive pulley 32 and an idler pulley 34, such that the tensioned portion of each belt 24, 26 intercepts the unidirectional tape 20.
  • discriminate lengths are cut or punched into the continuous fibers to produce multiple discontinuous fiber segments. The length of each discontinuous fiber segment can be dependent on the desired modulus and the desired formability of the finished tape.
  • the perforations occur with a frequency of between about 0.5 inches to about 1.0 inch, such that the continuous fibers are separated into discontinuous fiber segments having a length between about 0.5 inches to about 1.0 inch.
  • the discontinuous fiber segments can have a length outside of the above exemplary range.
  • the perforations are generally laterally elongate, being perpendicular to the direction of tape travel. The perforations terminate a predetermined distance from the lateral edges of the tape, optionally to within about 0.03125 inches from the lateral edges.
  • the perforated tape 20 is heated to above the molten temperature of the thermoplastic resin and immediately cooled and compressed to heal the thermoplastic resin.
  • pinch rollers 36 apply pressure to re-unify the perforations in the thermoplastic resin while additional rollers 38 cool the re-unified tape while also correcting surface finish and tape thickness.
  • the reunified tape 20 includes an upper surface and a lower surface, each surface being continuous and substantially free from surface discontinuities such as holes or slits.
  • first and second trimming wheels 40, 42 create respective slit lines along the length of the reunified tape 20, the slit lines intersecting brakes between discontinuous fiber segments.
  • the trimming wheels remove about 0.4 inches from the lateral edges of the reunified tape 20, while in other embodiments a greater or lesser amount can be removed.
  • the excess lateral edge portions 43 are taken up by winding spools 45.
  • the now-finished tape 20 is drawn through pull-rollers and taken up into spools 44.
  • the perforation operation includes separating continuous fibers into discontinuous fiber segments according to a repeating pattern of perforations.
  • the perforation pattern includes a first row 50 of five perforations 51 and a second row 52 of five perforations 53, where the first and second rows 50, 52 are laterally offset from each other.
  • Each perforation 51, 53 is repeated at 0.5 inch intervals, such that no single discontinuous fiber segment is longer than 0.5 inches.
  • Adjacent groups of discontinuous fiber segments 54, 56 are longitudinally offset from each other, such that no single perforation or break 51, 53 in the continuous fiber segments extends the width of the tape 20.
  • the perforation pattern of Fig. 4 is similar to the perforation pattern of Fig. 3, except that six perforations 51, 53 extend across the width of the tape 20.
  • the perforation pattern shown in Fig. 5 is also similar to the perforation pattern of Fig. 3, except that ten perforations 51, 53 extend across the width of the tape 20.
  • the perforation pattern of Fig. 6 includes a first row of fifteen perforations 51 and a second row of fifteen perforations 53, where the first and second rows partially overlap each other.
  • the perforation pattern of Fig. 7 includes three rows 50, 52, 60 of perforations 51, 53, 55 repeated at 0.5 inch intervals. Each row includes seven perforations, and each is row is laterally offset from the adjacent row of perforations.
  • adjacent discontinuous fiber segments are longitudinally offset from each other in some embodiments, while in other embodiments adjacent groups of discontinuous fiber segments are longitudinally offset from each other.
  • the finished fiber-reinforced tape 20 generally includes a plurality of discontinuous fiber segments extending unidirectionally in longitudinal columns within a thermoplastic matrix material.
  • the fiber-reinforced tape 20 is substantially free of fibers that are angled relative to the tape longitudinal axis, and in particular, substantially free of fibers oriented at angle of greater than 5 degrees relative to the tape longitudinal axis.
  • the fiber- reinforced tape 20 is substantially free of continuous fibers, with each fiber segment being less than about 5 inches, further optionally less than about 2 inches, and still further optionally between about 0.5 inches and about 1.0 inches. Adjacent groups of discontinuous fiber segments are longitudinally offset from each other as noted above in connection with Figs. 3-7.
  • the fiber-reinforced tape 20 can assume a number of dimensions based on the needs of the particular application.
  • the finished tape can define a width of at least about 0.125 inches, optionally about 2.0 inches.
  • the fiber- reinforced tape 20 can define a thickness of between about 0.005 inches and about 0.075 inches, optionally between about 0.14 inches and about 0.028 inches, and further optionally about 0.024 inches. In other embodiments, the fiber-reinforced tape 20 can vary outside of these ranges, however.
  • a method for forming a woven panel 70 generally includes providing a first plurality of laterally spaced apart fiber-reinforced weft strips 72, providing a first plurality of laterally spaced apart fiber-reinforced warp strips 74, and interweaving the weft and warp strips 72, 74.
  • Each of the weft and warp strips 72, 74 are formed according to the method set forth above in connection with Figs. 1-2.
  • each of the weft and warp strips 72, 74 include a plurality of discontinuous fiber segments extending unidirectionally within a thermoplastic matrix material.
  • the weft and warp strips 72, 74 are optionally identical to each other, providing a woven panel 70 with a desired overall width and fiber to resin ratio.
  • the woven panel 70 can be used as a single sheet, for example in an insert molding process.
  • the woven panel 70 can also be combined with other woven panels.
  • a second woven panel 76 can include a second plurality of laterally spaced apart fiber-reinforced weft strips 72 and a second plurality of laterally spaced apart fiber-reinforced warp strips 74.
  • the first and second woven panels 70, 76 can be consolidated using a press, a laminator, nip rolls, or a belt press.
  • Each panel includes an alternating orientation of 0° and 90° as perhaps best shown in Fig. 9.
  • a third woven panel 78 is also shown as being consolidated to form a multi-layered mat 80.
  • Each panel within the mat 80 can contain films on the exterior surfaces and/or between woven panels to achieve product variability.
  • a surface film can achieve a paintable or class "A" surface.
  • Films can be placed between the woven panels 70, 76, 78 to increase impact resistance or toughness. These films or layers would normally be destroyed in a high pressure molding situation. In the present embodiment, however, these films and layers can remain intact without deformation due to the lower pressure molding of the multi-layered mat 80.
  • the fiber-reinforced tape 20 can be placed in a low- pressure mold 82.
  • a heated die 84 for example hydro-form or low- diameter plug
  • the mat 80 is heated to the point that the impregnation polymer melts, the embedded discontinuous fiber segments slip, allowing the fiber segments to move in a discriminate and controlled manner. Since the multi-layered mat 80 is under relatively low pressure, each fiber segment is constrained by the adjacent fiber segments, and is only allowed to move in the direction it is oriented.
  • each layer of the multi-layered woven mat 80 expand orthogonally relative to the adjacent layer.
  • the fiber segments give, they pull apart from each other, allowing the molding material to move into cavities or corners within the mold cavity. Warpage is minimized because the fiber segments are not free to move in any direction, but are confined in the direction of fiber orientation.
  • thermoplastic matrix and the reinforcing fibers can influence the physical properties of the composite structure. For example, temperature resistance, solvent resistance, and impact resistance can be tailored into the fiber-reinforced tape.
  • the fiber segment length and fiber to resin ratio can influence the mechanical properties of the composite structure, including the strength and the modulus.
  • the fiber-reinforced tape of the present invention can provide composite part designers with a range of material options not otherwise available in the manufacture of complex composite structures.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Reinforced Plastic Materials (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

La présente invention concerne des matériaux de moulage renforcés de fibres et un procédé connexe de fabrication. Les matériaux de moulage renforcés de fibres comprennent un ruban renforcé de fibres qui peut être moulé en de structures complexes à des pressions relativement basses tout en présentant des concentrations en fibre élevées. Le ruban renforcé de fibres comprend une pluralité de segments de fibre discontinus qui s'étendent de façon unidirectionnelle à l'intérieur d'un matériau de matrice thermoplastique. Le ruban renforcé de fibres peut être entrelacé en de multiples panneaux tissés qui sont consolidés pour former un mat renforcé de fibres. Le mat renforcé de fibres est approprié pour une large gamme d'applications de moulage où une haute résistante et un poids léger sont souhaités, tout en étant adapté à une variété de fibres de renforcement et résines thermoplastiques.
PCT/US2013/074561 2012-12-28 2013-12-12 Matériaux de moulage thermoplastiques à basse pression pour structures composites renforcées de fibres WO2014105437A1 (fr)

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US13/729,101 US20140186600A1 (en) 2012-12-28 2012-12-28 Low pressure thermoplastic molding materials for fiber-reinforced composite structures
US13/729,101 2012-12-28

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CN105579223B (zh) 2013-07-24 2018-09-14 综合复合产品股份有限公司 复合结构制品
JP2015182202A (ja) * 2014-03-25 2015-10-22 日本発條株式会社 繊維強化樹脂板の打ち抜き方法及び繊維強化樹脂部品の製造方法
US10195818B2 (en) 2014-08-13 2019-02-05 Integrated Composite Products, Inc. Reinforcing article
US10086571B2 (en) 2015-02-12 2018-10-02 Integrated Composite Products, Inc. Pre-stressed fiber reinforcing member and method for its manufacture
DE102015204142A1 (de) * 2015-03-09 2016-09-15 Bayerische Motoren Werke Aktiengesellschaft Verfahren zur Herstellung von faserverstärkten Kunststoffbauteilen
US10596778B2 (en) 2015-04-13 2020-03-24 Howard E. Crawford, III Fiber-reinforced composite material
EP4170078A1 (fr) * 2016-05-16 2023-04-26 Georgia Tech Research Corporation Systèmes et procédés de fabrication continue de matériaux composites tissés
EP3521011A1 (fr) * 2018-01-31 2019-08-07 SABIC Global Technologies B.V. Procédés de réduction de déchets pour fabriquer des stratifiés à partir de rubans et stratifiés fabriqués selon lesdits procédés

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