WO2017198571A1 - Matériaux de moulage - Google Patents

Matériaux de moulage Download PDF

Info

Publication number
WO2017198571A1
WO2017198571A1 PCT/EP2017/061501 EP2017061501W WO2017198571A1 WO 2017198571 A1 WO2017198571 A1 WO 2017198571A1 EP 2017061501 W EP2017061501 W EP 2017061501W WO 2017198571 A1 WO2017198571 A1 WO 2017198571A1
Authority
WO
WIPO (PCT)
Prior art keywords
fibres
core
moulding material
grid
material according
Prior art date
Application number
PCT/EP2017/061501
Other languages
English (en)
Inventor
Thomas James
Oliver Wessely
Original Assignee
Hexcel Reinforcements Uk Limited
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 Hexcel Reinforcements Uk Limited filed Critical Hexcel Reinforcements Uk Limited
Priority to DE112017002490.0T priority Critical patent/DE112017002490T5/de
Publication of WO2017198571A1 publication Critical patent/WO2017198571A1/fr

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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • 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
    • B29C70/06—Fibrous reinforcements only
    • 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
    • B29C70/14—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 oriented
    • 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
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/18—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length in the form of a mat, e.g. sheet moulding compound [SMC]
    • 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
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • B29C70/224—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure the structure being a net
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B29D99/0014—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B29D99/0014—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs
    • B29D99/0017—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs with filled hollow ridges
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • B32B3/085—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts spaced apart pieces on the surface of a layer
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/14—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/14—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side
    • B32B3/16—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side secured to a flexible backing
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the 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
    • 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
    • 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
    • B32B5/12—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 the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • 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
    • 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
    • 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
    • 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
    • B32B5/28—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 impregnated with or embedded in a plastic substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3002—Superstructures characterized by combining metal and plastics, i.e. hybrid parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 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
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • 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
    • B32B2262/10—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
    • B32B2307/50—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
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • 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
    • 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
    • B32B2605/08—Cars

Definitions

  • the present invention relates to curable moulding materials and cured components produced therefrom, particularly moulding materials and components for use in forming vehicle components such as body panels and fairings.
  • HGVs heavy goods vehicles
  • aerodynamic structures also known as fairings
  • a particular example is a sloping roof on a HGV, which can save as much as 7% of the fuel costs.
  • Such structures may be formed integrally with the bodywork during initial manufacture or may be added at later stages.
  • the aerodynamic structures In order to withstand the stresses encountered during operation of the vehicle, the aerodynamic structures must have high strength and stiffness, but if they are too heavy the increased weight of using such structures will have a negative effect on fuel consumption.
  • the safety and resilience of vehicles can be improved by incorporating reinforcing body panels having high strength and/or stiffness into the vehicles, but if such panels increase the weight of the vehicles they will have a negative impact on fuel consumption and/or handling properties of the vehicles.
  • reinforcing vehicle body panels and fairings are produced from materials comprising a core material sandwiched between two layers of chopped strand mat, a non-woven material consisting of glass fibres laid randomly across each other.
  • This material may be shaped in a mould and then infused with a curable resin, which is cured to form the final cured composite product.
  • This process is effectively a single step process, and is particularly convenient when the core and chopped strand mat are provided as a single component ready for moulding/resin infusion, i.e. with the chopped strand mat attached to the core, for example by stitching.
  • the core material the thickness of chopped strand mat and the type and amount of resin used, the final properties of the cured material may be adjusted.
  • chopped strand mat comprising glass fibres is a relatively heavy material, and there is an inevitable trade-off between providing good strength and/or stiffness whilst not increasing the weight of the final material to unacceptable levels.
  • the present invention aims to obviate or at least mitigate the above described problems and/or to provide advantages generally.
  • the present invention provides a moulding material comprising a core comprising two opposing surfaces, wherein at least one of the opposing surfaces of the core is covered by a grid of continuous fibres.
  • the present invention provides a method of forming a cured component comprising infusing a moulding material according to the present invention with a curable resin and curing the curable resin.
  • the present invention provides a cured component obtainable by the method of the present invention.
  • the present invention provides a vehicle component comprising a cured component according to the present invention or obtained by the method of the present invention, preferably wherein the vehicle component is a body panel or a fairing.
  • a grid formed from continuous fibres covering at least one of the surfaces of the core in the moulding materials of the present invention improves the strength and/or stiffness of the core, and therefore such materials may be used directly as moulding materials by being infused with a suitable curable resin.
  • one of both of the surfaces of the core may be covered by a covering layer before being infused with resin, and the covering layer may be any material contributing to the final properties of the moulding materials after resin infusion/curing.
  • the covering materials are conventional materials, such as chopped strand mat
  • lower amounts of such materials are required to produce comparable strength/stiffness compared to conventional materials because of the presence of the grid, and therefore strength/stiffness may be maintained at conventional levels whilst reducing the weight of the moulding materials, or moulding materials of conventional weight may be produced but having increased strength/stiffness.
  • moulding materials having improved strength/stiffness and reduced weight compared to conventional materials may be produced.
  • at least one of the opposing surfaces of the core is covered by a grid of continuous fibres, i.e.
  • continuous fibres it is meant that each individual fibre is unbroken along the length or breadth of the grid, but it is not necessary that all of the strands of the grid running in a particular direction are formed from a single fibre (although this is possible in certain embodiments).
  • the grid may be formed from a first set of parallel, separate, unbroken/continuous fibres running in a first direction, and a second set of parallel, separate, unbroken/continuous fibres running in a different, preferably
  • the parallel fibres are spaced apart by a distance of from 5 to 100mm, more preferably from 20 to 50mm.
  • the fibres may be in the form of a grid having 25mm square spaces between the fibres.
  • the fibres forming the grid may be unconnected, i.e. fibres running in one direction are simply placed on top of fibres running in a generally perpendicular direction, or they may be connected at the crossing points. Where the fibres are connected, this may be by any suitable means, such as by weaving fibres together, or, more preferably, by use of an adhesive or by stitching, or they may be comingled and heat-set.
  • the grids covering at least one surface of the core of moulding materials according to the present invention may be formed from any fibrous materials providing improved strength and/or stiffness to the final cured component.
  • suitable materials include carbon, glass, aramid and natural fibres, such as cellulose fibres, or combinations thereof.
  • the materials may be mixed in each fibre of the grid, or different grid fibres may be formed from different materials, for example all of the fibres running in a first orientation of the grid may be made from a first material and all of the fibres running in a second orientation of the grid may be made from a second material.
  • the grid covering at least one of the opposing faces of the core material comprises carbon fibres.
  • the grid may comprise any suitable carbon fibres, but generally the carbon fibres will be in the form of commercially available carbon fibre tows, i.e. bundles of multiple carbon fibre filaments.
  • the carbon fibre filaments may be of conventional size, such as approximately 7 ⁇ in diameter and each tow may comprise any number of individual filaments, but preferably each tow comprises approximately the same number of filaments, preferably ranging from 1,000 to 50,000 filaments per tow, although even higher numbers of filaments per tow are possible.
  • the tows are of suitable length so that the grid matches the dimensions of the core in the finished cured component.
  • the non-carbon fibres may be any suitable material, such as glass, aramid or natural fibres; for example at least a portion of the fibres may be glass fibres.
  • any suitable glass fibres may be present, such as commercially available glass fibres.
  • the grid of continuous fibres is in contact with the surface of the core, and in a particularly preferred embodiment the grid is located in channels on the surface of the core.
  • the channels on the surface of the core may be of any size suitable for the fibres to fit into, but are preferably only slightly wider than the fibres, so that the fibres fit into the channels relatively tightly.
  • the channels may be pre-formed during the
  • the grid may simply be placed in contact with the surface of the core before the infusion of resin into the moulding material during construction of the final cured component, or alternatively, the grid may be attached to the core.
  • the grid may be attached to the core in any suitable way, such as by being covered by a layer which is attached to the core and therefore holds the grid in place, or by direct attachment, such as by stitching or bonding.
  • both opposing surfaces of the core are covered by grids of continuous fibres.
  • the two grids of continuous fibres may be the same or different, but preferably at least one of the grids of continuous fibres, and more preferably both grids of continuous fibres, comprise carbon fibres.
  • At least one of the two opposing surfaces of the core is covered by a covering layer, and most preferably the at least one surface covered by a grid of continuous fibres is also covered by a covering layer which also covers the grid of continuous fibres.
  • At least one of the opposing surfaces of the core is covered by a layer of randomly orientated short fibres, preferably so that the layer of randomly orientated short fibres covers the at least one grid of continuous fibres.
  • the fibres forming the layer of randomly orientated short fibres used in the preferred embodiments of the present invention may be of similar lengths to the fibres used in conventional chopped strand mats, but preferably the fibres are from 5 to 150mm in length, more preferably from 25 to 75mm.
  • the short fibres may comprise any suitable material providing strength and/or stiffness to the finished product.
  • Suitable materials include carbon fibres, glass fibres, aramid fibres and natural materials such as cellulose fibres.
  • at least a portion of the fibres of the layers of randomly orientated short fibres are carbon fibres and, optionally, substantially all of the fibres of the layer of randomly orientated short fibres may be carbon fibres.
  • from 5 to 100% of the fibres of the layer of randomly orientated short fibres may be carbon fibres, preferably from 10 to 100%, and more preferably from 50 to 100%.
  • the carbon fibres forming at least a portion of the fibres in the layers of randomly orientated short fibres in the moulding materials according to this embodiment of the present invention may be any suitable carbon fibres, but generally will be in the form of commercially available carbon fibre tows, i.e. bundles of multiple carbon fibre filaments.
  • the carbon fibre filaments may be of conventional size, such as approximately 7 ⁇ in diameter and each tow may comprise any number of individual filaments, but preferably each tow comprises approximately the same number of filaments, preferably ranging from 1,000 to 50,000 filaments per tow.
  • the tows may be any suitable length, but are preferably within the range of from 5 to 150mm in length, more preferably from 25 to 75 mm in length.
  • At least a portion of the carbon fibres in the layer of randomly orientated short fibres are carbon fibres at least a portion of the carbon fibres are recycled carbon fibres and, optionally, substantially all of the carbon fibres may be recycled carbon fibres.
  • Recycled carbon fibres may be produced by any suitable methods, and are preferably produced from processing waste or end-of-life sources. The use of recycled carbon fibres provides potential cost reductions and/or a convenient use for recycled materials rather than disposal thereof. Suitable recycled carbon fibres, chopped recycled carbon fibres and layers of randomly orientated short fibres comprising recycled carbon fibres can be obtained from Carbon Conversions, Lake City, South Carolina, USA.
  • the non-carbon fibres may be any suitable material, such as glass, aramid or natural fibres; for example at least a portion of the fibres of the layer of randomly orientated short fibres may be glass fibres or, optionally, substantially all of the randomly orientated short fibres may be glass fibres.
  • from 5 to 100% of the fibres of the layer of layer of randomly orientated short fibres may be glass fibres, preferably from 5 to 90%, and more preferably from 5 to 50%.
  • any suitable glass fibres may be present, such as commercially available glass fibres, but the fibres should substantially all have lengths in the range of from 5 to 150mm, preferably from 25 to 75mm.
  • the layers of randomly orientated short fibres used in this embodiment of the moulding materials of the present invention may comprise additional materials, such as any conventional materials used in commercially available chopped strand mats, including binders, such as starch emulsion binders, and stitching, such as polyester stitching.
  • additional materials such as any conventional materials used in commercially available chopped strand mats, including binders, such as starch emulsion binders, and stitching, such as polyester stitching.
  • Carbon fibres are generally lighter, stronger and/or stiffer than glass fibres, and therefore, when at least a portion of the randomly orientated short fibres in the covering layers of the moulding materials of the present invention are carbon fibres, it is possible to use reduced amounts of the covering materials compared to conventional moulding materials not comprising carbon fibres, whilst maintaining comparable strength/stiffness, and this is particularly advantageous in combination with the additional strength and/or stiffness provided by the grid of continuous fibres also present in moulding materials of the present invention.
  • moulding materials having weights after resin infusion and curing of from 25% to 95% of conventional non-grid/non-carbon fibre containing materials, but having comparable strength/stiffness to the conventional materials may be obtained by the present invention.
  • lighter covering materials may be used to produce moulding materials for forming finished products having increased strength/stiffness, but comparable weights, to conventional non-grid/non-carbon fibre containing materials.
  • moulding materials for forming finished products having increased strength/stiffness and reduced weight compared to conventional non-grid/non-carbon fibre containing materials may be obtained.
  • the layer of randomly orientated short fibres may be unattached to the core until the resin infusion/bonding step; however, in preferred embodiments the layer of randomly orientated short fibres is attached to the surface of the core before the resin infusion stage.
  • the layer of randomly orientated short fibres may be attached to the surface of the core in any conventional manner, such as by use of a binder/adhesive, for example a thermoplastic binder, or by stitching.
  • the layer of randomly orientated short fibres may be attached to the core by stitching using any suitable stitching process, such as conventional stitching processes by which chopped strand mat is attached to cores in conventional products.
  • At least one of the two opposing surfaces of the core is covered by a layer of randomly orientated short fibres, and more preferably any surface of the core covered by a grid of continuous fibres is also covered by a layer of randomly orientated short fibres, particularly so that the grid of continuous fibres is covered by the layer of randomly orientated short fibres.
  • both opposing surfaces of the core are covered, and, more preferably, both opposing surfaces of the core are covered by layers comprising randomly orientated short fibres, and, most preferably at least a portion of the randomly orientated short fibres of each of the two layers of randomly orientated short fibres are carbon fibres.
  • Different properties may be provided to different surfaces of the moulding materials according to the present invention by applying different layers to the two opposing faces, and any combination of the surface layers discussed above may be used.
  • Any suitable material may be used as a core in moulding materials according to the present invention.
  • the core is at least partially permeable in order to allow at least partial penetration into the core of resin during infusion/curing.
  • the core of the moulding materials of the present invention is preferably flexible.
  • the core is sufficiently flexible that the moulding materials of the present invention are mould conformable, i.e. that the moulding materials may be pressed into a shaped mould and will conform to the shape of the mould.
  • the cores used in moulding materials according to the present invention are elastically compressible, so that when a moulding material according to this embodiment is compressed to fit into a tight fitting mould the core will expand causing the moulding material to fill the mould, thereby expelling air from the mould and ensuing that the component produced in the mould matches the shape of the mould.
  • Suitable materials for forming the core of moulding materials according to the present invention include balsa, open-cell and closed-cell foam materials and composite materials, and particularly preferred core materials include polypropylene, such asHacoloft ® PP available from Ziegler, and polyester, such as Soric ® SF available from Lantor.
  • the cores used to form moulding materials according to the present invention may be any suitable thickness, shape and size.
  • Preferred core thicknesses are from 1 to 100mm, more preferably from 3 to 30mm, but preferably, in embodiments in which the grid of continuous fibres is located in channels on the surface of the core, the core is sufficiently thick that the channels do not significantly reduce the strength/stiffness of the core.
  • Possible core shapes include square, oblong, circular and oval, but in embodiments in which at least one of the two opposing surfaces of the core is covered by a layer of randomly orientated short fibres, the core is in the form of a sheet having a much greater length than width, so that the moulding materials may be produced in an effectively continuous process, i.e.
  • a roll of core material may be gradually unwound while a grid of continuous fibres and a layer of randomly orientated short fibres are applied to at least one face of the core and, optionally, are attached thereto, before the covered core is cut to the final shape.
  • the core is at least 50mm wide and up to any length that may be produced or stored as a roll, such as 1.25 metres wide and 22 metres long.
  • cured components according to a third aspect of the present invention may be obtained by infusing a moulding material according to the present invention with a curable resin and curing the curable resin.
  • any suitable resin may be used to form cured components according to the present invention, but preferred resins include low viscosity resins, particularly low viscosity epoxy resins or low viscosity polyester resins, such as Crystic ® from Scott Bader or Aropol ® from Ashland.
  • the infusion of moulding materials according to the present invention with a curable resin may be carried out in any suitable way, such as in a mould and by using increased pressure and/or vacuum to improve penetration of the curable resin at least partially into the core and the grid of continuous fibres, and also into any layers of randomly orientated short fibres present in the moulding material.
  • Curing of the curable resin may also be carried out in any suitable manner, such as by use of curing agents and/or increased temperature.
  • a resin and a curing agent are mixed immediately before infusion into a moulding material according to the present invention, the infusion preferably being carried out in a mould, and curing of the infused resin optionally being enhanced by a steady increase in temperature within the mould.
  • Cured components according to the present invention and/or obtained by the methods of the present invention may be used as vehicle components, particularly as body panels or fairings to provide light weight reinforcement and/or aerodynamic surfaces, particularly for HGVs.
  • Cured components obtained by the processes of the present invention may be ready to use as vehicle components, or they may be further processed before use, for example by reshaping, changing the surface properties and/or by the addition of additional surface materials.
  • Figure 1 shows a diagrammatic cross-sectional view of a moulding material according to a first embodiment of the present invention
  • Figure 2 shows a diagrammatic cross-sectional view of a moulding material according to a second embodiment of the present invention
  • Figure 3 shows a diagrammatic cross-sectional view of a moulding material according to a third embodiment of the present invention.
  • Figure 1 shows a moulding material 1 according to a first embodiment of the present invention.
  • the moulding material 1 comprises a core 3 which is a Hacoloft ® polypropylene core available from Ziegler.
  • a first face 5 of the core 3 is covered by a carbon fibre grid 7, which is a flat grid formed from two sets of parallel carbon fibres with a 25mm spacing between fibres, arranged perpendicularly to each other to form a grid with square spaces measuring 25mm by 25mm.
  • the individual fibres forming the carbon fibre grid 7 are all continuous fibres, i.e. they are unbroken along their length.
  • the carbon fibre grid 7 is attached to the core 3 by stitching (not shown).
  • the moulding material 1 shown in Figure 1 may be converted to a construction component suitable to form a vehicle body panel or a fairing by infusion with a curable resin such as Crystic ® from Scott Bader or Aropol ® from Ashland in a mould and by subsequent curing.
  • a curable resin such as Crystic ® from Scott Bader or Aropol ® from Ashland in a mould and by subsequent curing.
  • FIG 2 shows a moulding material 9 according to second embodiment of the present invention.
  • the moulding material 9 comprises a core 3 which is a polypropylene core similar to the core 3 shown in Figure 1.
  • the core 3 may be a different core material such as a Soric ® SF polyester core available from lantor.
  • a first face 5 of the core 3 is covered by a carbon fibre grid 7 similar to the grid 7 shown in Figure 1.
  • the carbon fibre grid 7 may be replaced by a grid of continuous fibres formed from any other suitable material, such as a glass fibre grid.
  • the first face 5 of the core 3 is also covered by a layer of randomly orientated short fibres 11, which also covers the carbon fibre grid 7.
  • Substantially all of the fibres of the layer of randomly orientated short fibres 11 are carbon fibres having lengths of approximately 50mm.
  • the carbon fibres are recycled carbon fibres obtained from ELG Carbon Fibre, Carbiso M, producing a coating thickness of approximately 0.5mm.
  • the recycled carbon fibres in the layer of randomly orientated short fibres can be obtained from carbon Conversions, lake City, south Carolina, USA.
  • up to 95% of the fibres of the layer of randomly orientated short fibres 11 may be replaced by alternative fibres, such as glass fibres.
  • the layer of randomly orientated short fibres 11 is attached to the first face 5 of the core 3 by stitching with polyester yarn from J. H. Ashworth (not shown).
  • the stitching also holds the carbon fibre grid 7 in contact with the first face 5 of the core 3.
  • the opposing face 13 of the core 3 is also covered by a carbon fibre grid 15 which is similar to the carbon fibre grid 7 covering the first face 5 of the core 3, but alternatively, the carbon fibre grid 15 may be replaced by a grid of continuous fibres formed from any other suitable material, such as a glass fibre grid.
  • a covering layer 17 covers the opposing face 13 of the core 3 and the carbon fibre grid 15.
  • the covering layer 17 covering the opposing face 13 of the core 3 is the same as the layer 11 covering the first face 5 of the core 3, but in alternative embodiments the layer 17 may be formed from any materials, such as conventional chopped strand mat, or may be a layer of randomly orientated short fibres in which some of the fibres are carbon fibres and some of the fibres are glass fibres.
  • the layer covering 17 may be attached to the opposing face 13 of the core 3 by stitching in the same manner as the first layer 11 is attached to the first face 5 of the core 3, but alternatively the covering layer 17 may be attached to the core 3 during the resin infusion/curing step, the resin passing through the grid 15 and adhering the covering layer 17 to the second face 13 of the core 3.
  • the moulding material 9 shown in Figure 2 may be converted to a construction component suitable to form a vehicle body panel or a fairing by infusion with a curable resin such as Crystic ® from scott Bader in a mould and by subsequent curing.
  • a curable resin such as Crystic ® from scott Bader in a mould
  • FIG. 3 shows a moulding material 19 according to a third embodiment of the present invention.
  • the moulding material 19 comprises a core 21 which is a polypropylene core similar to the core 3 shown in Figure 1, or a polyester core 3 similar to the alternative core discussed with respect to Figure 2.
  • the core 21 additionally comprises channels 23 in each of the two opposing surfaces 25 and 27 of the core 21.
  • the channels 23 comprise longitudinal and perpendicular channels 23 with a spacing between adjacent channels 23 of 25mm, and therefore form a grid pattern in each of the two opposing surfaces 25 and 27 of the core 21.
  • the channels 23 have a width of 10mm and a depth of 5mm, and entirely cover each of the two opposing surfaces 25 and 27 of the core 19.
  • a carbon fibre grid 29 is located within the channels 23 on each of the two opposing surfaces 25 and 27 of the core 21.
  • the carbon fibre grid 29 is similar to the carbon fibre grid 7 shown in Figure 2.
  • Both faces 25 and 27 of the core 21 are also covered by a layer of randomly orientated short fibres 31, which also cover the carbon fibre grids 29.
  • the layers of randomly orientated short fibres 31 are similar to the layer of randomly orientated short fibres 11 shown in Figure 2 or the alternative covering layers 17 discussed therein.
  • the covering layers 31 are attached to the core 21 by stitching, as discussed with respect to Figure 2.
  • the moulding material 19 shown in Figure 3 may be converted to a construction component suitable to form a vehicle body panel or a fairing by infusion with a curable resin such as Crystic ® from Scott Bader in a mould and by subsequent curing.
  • a moulding material generally corresponding to the material shown in Figure 2 was produced comprising a polypropylene core with both opposing faces of the core covered by a grid of continuous carbon fibres having a spacing between adjacent fibres of 25mm. Each face was also covered by a layer of randomly orientated short carbon fibres (Carbicore 200) which completely covered the grid on each face.
  • the flexural strength (ultimate bending moment) and flexural stiffness (section modulus) were measured as well as the areal mass. These properties were compared to a moulding material comprising the same core covered by layers of commercially available chopped strand glass mat (CPPC300) and with no grid present. The results are shown in Table 1 below. Table 1

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Textile Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Moulding By Coating Moulds (AREA)
  • Reinforced Plastic Materials (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un matériau de moulage, lequel matériau comprend un cœur comprenant deux surfaces opposées, au moins l'une des surfaces opposées du cœur étant recouverte par une grille de fibres continues. Le matériau de moulage peut être utilisé pour former un élément de véhicule tel qu'un panneau de carrosserie ou un carénage ayant des propriétés de résistance et/ou de poids améliorées.
PCT/EP2017/061501 2016-05-16 2017-05-12 Matériaux de moulage WO2017198571A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
DE112017002490.0T DE112017002490T5 (de) 2016-05-16 2017-05-12 Formwerkstoffe

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB1608566.4A GB2550357A (en) 2016-05-16 2016-05-16 Moulding materials
GB1608566.4 2016-05-16

Publications (1)

Publication Number Publication Date
WO2017198571A1 true WO2017198571A1 (fr) 2017-11-23

Family

ID=56320461

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2017/061501 WO2017198571A1 (fr) 2016-05-16 2017-05-12 Matériaux de moulage

Country Status (3)

Country Link
DE (1) DE112017002490T5 (fr)
GB (1) GB2550357A (fr)
WO (1) WO2017198571A1 (fr)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5632844A (en) * 1993-02-05 1997-05-27 Gencorp Inc. Acoustic lamina wall covering
WO2001055524A1 (fr) * 2000-01-25 2001-08-02 Isosport Verbundbauteile Gesellschaft M.B.H. Composant et son procede de production
WO2002058915A1 (fr) * 2001-01-26 2002-08-01 Kaneka Corporation Materiau de noyau pour structure composite en resine renforcee par des fibres et procede de production d'une structure composite en resine renforcee par des fibres a l'aide de ce materiau
FR2834927A1 (fr) * 2002-01-18 2003-07-25 Chomarat Composites Nouvelle mousse renforcee par un reseau de renforcement
EP2317126A2 (fr) * 2009-10-30 2011-05-04 General Electric Company Procédés de fabrication de pales d'une éolienne et autres structures
WO2012163690A1 (fr) * 2011-05-27 2012-12-06 Gurit (Uk) Ltd Âme de mousse pour objet stratifié composite, et son procédé de fabrication

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5632844A (en) * 1993-02-05 1997-05-27 Gencorp Inc. Acoustic lamina wall covering
WO2001055524A1 (fr) * 2000-01-25 2001-08-02 Isosport Verbundbauteile Gesellschaft M.B.H. Composant et son procede de production
WO2002058915A1 (fr) * 2001-01-26 2002-08-01 Kaneka Corporation Materiau de noyau pour structure composite en resine renforcee par des fibres et procede de production d'une structure composite en resine renforcee par des fibres a l'aide de ce materiau
FR2834927A1 (fr) * 2002-01-18 2003-07-25 Chomarat Composites Nouvelle mousse renforcee par un reseau de renforcement
EP2317126A2 (fr) * 2009-10-30 2011-05-04 General Electric Company Procédés de fabrication de pales d'une éolienne et autres structures
WO2012163690A1 (fr) * 2011-05-27 2012-12-06 Gurit (Uk) Ltd Âme de mousse pour objet stratifié composite, et son procédé de fabrication

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
DATABASE WPI Week 200265, Derwent World Patents Index; AN 2002-608423, XP002772987 *

Also Published As

Publication number Publication date
GB201608566D0 (en) 2016-06-29
GB2550357A (en) 2017-11-22
DE112017002490T5 (de) 2019-02-28

Similar Documents

Publication Publication Date Title
US9631501B2 (en) Wind turbine blade comprising metal filaments and carbon fibres and a method of manufacturing thereof
US7815160B2 (en) Composite mandrel
US8840988B2 (en) Fiber preform made from reinforcing fiber bundles and comprising unidirectional fiber tapes, and composite component
DK1802453T3 (en) Infusionsstof for forming large composite structures
EP2661357B1 (fr) Préforme de stratifié pour pale de turbine éolienne et procédé pour sa fabrication
US7930907B2 (en) Crimp-free infusible reinforcement fabric and composite reinforced material therefrom
EP1798428A1 (fr) Pièce composite fabriquée par tissage
CN117984688A (zh) 用于复合轮的辐条部分的成形预制件
GB2387810A (en) Preform composite moulding materials
KR20150093745A (ko) 비-꼬임 섬유를 포함하는 물품 및 물품 사용 방법
US20160023405A1 (en) Method and Device for Producing a Fiber Composite Component and Fiber Composite Component
KR100916020B1 (ko) 몰딩 방법
JP2015178241A (ja) 繊維強化樹脂材の製造方法
EP2410576A2 (fr) Composant composite avec une couche solaire active et procédé de fabrication d'un composant composite
US3898113A (en) Method of making a continuous strand sheet molding compound
CN104859215A (zh) 复合材料及其制造和使用方法
EP1667838B1 (fr) Tissu de renfort infusable non plissé et procédé pour sa fabrication
WO2017198568A1 (fr) Matériaux de moulage
WO2017198571A1 (fr) Matériaux de moulage
CN111086234A (zh) 热塑性复合材料和复合材料部件及其制造方法
US20060194034A1 (en) Method for the production of fiber composites and fiber composite produced according to said method
JPH074880B2 (ja) 樹脂含浸繊維基材および繊維強化プラスチツクの製造法
US20220388274A1 (en) Moulding material
CN109940903A (zh) 一种碳纤维复合板成型工艺
CN115352091A (zh) 一种玻纤碳纤复合拉挤板材

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 17723111

Country of ref document: EP

Kind code of ref document: A1

122 Ep: pct application non-entry in european phase

Ref document number: 17723111

Country of ref document: EP

Kind code of ref document: A1