Classifications

• • 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
• • 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
  • D03D1/00—Woven fabrics designed to make specified articles
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
  • D03D13/004—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft with weave pattern being non-standard or providing special effects
• • 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
  • D03D15/20—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 material of the fibres or filaments constituting the yarns or threads
  • D03D15/283—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 material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2101/00—Inorganic fibres
  • D10B2101/02—Inorganic fibres based on oxides or oxide ceramics, e.g. silicates
  • D10B2101/06—Glass
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2101/00—Inorganic fibres
  • D10B2101/10—Inorganic fibres based on non-oxides other than metals
  • D10B2101/12—Carbon; Pitch
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
  • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
  • D10B2331/021—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides aromatic polyamides, e.g. aramides
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2401/00—Physical properties
  • D10B2401/04—Heat-responsive characteristics
  • D10B2401/041—Heat-responsive characteristics thermoplastic; thermosetting
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2505/00—Industrial
  • D10B2505/02—Reinforcing materials; Prepregs

Definitions

• the present invention relates to a production method which is developed in order to be used as structural and visual material in all industrial fields, mainly aviation, defense industry, medical, marine and automotive, and which enables the non- crimp dry fabric formed with a yarn that is manufactured from at least unidirectional reinforcing fibers to be stabilized via the meltable thermoplastic yarn as resin.
• the layers forming the non-crimp fabric are formed by including the thermoplastic yarn in weft and warp direction into the system.
• thermoset composites are structures comprised of thermoset resin impregnated yarns manufactured from reinforcing fibers.
• thermoplastic composites are structures comprised of thermoplastic resin impregnated yarns manufactured from reinforcing fibers.
• the composites are very popular today due to their lightweight, reducing emission values, and resistance against corrosion properties.
• the resin used in stabilizing textiles comprising reinforcing fiber used in composite sector is applied as liquid or powder.
• the bulk textile product which is obtained is then transformed into composite material which is the final product which production methods such as thermal and/or pressure forming.
• yarns such as polyamides (PA) (polyamide 6 (PA6), polyamide 6,6 (PA66), polyphthalamide (PPA)), polyphenylene sulfide (PPS), polysulfone (PSU) polyarylenethersulfone, polyolefines (polyethylene (PE), polypropylene (PP) etc.), polyimide (PI), polyesters, preferably such as polyethylene terephthalate (PET) or polybutylene terephthalate (PBT), polyether ether ketone (PEEK) can be used.
• PA polyamides
• PA6 polyamide 6
• PA66 polyphthalamide
• PPS polyphenylene sulfide
• PSU polysulfone
• PI polysulfone
• polyesters preferably such as polyethylene terephthalate (PET) or polybutylene terephthalate (PBT), polyether ether ketone (PEEK)
• PET polyethylene terephthalate
• PBT polybut
• the production method used in stabilizing the textiles comprising reinforcing fiber can be performed with discontinuous process or continuous process.
• discontinuous and continuous methods even in case of feeding the powder and liquid resin is automatic, the resin/reinforcing fiber ratio cannot be applied in the desired accuracy since the amount of resin to be used is quite low. Variations occur in the resin amounts used in unit area.
• the objective of the present invention is to provide a production method which enables resin used in stabilization application of the non-crimp fabrics obtained from reinforcing fiber containing yarns to better impregnate into the structure, that is to better stabilize the reinforcing yarns relative to the conventional applications.
• the resin is applied in meltable thermoplastic yarn form.
• Another objective of the present invention is to enable the reinforcing structure to provide ease of use during composite production and the composite material to have more homogenous strength values. Complex composite parts can easily be manufactured with the dry fabric obtained by means of this production method.
• the most important advantage of the invention is to allow production of non- crimp fabric in standard weaving machines or hand looms without requiring multiaxial textiles production machine.
• FIG. 1 The detailed view of biaxial structure which is subjected to the inventive stabilized reinforcing textile fabric production method when the angles of the layers of non-crimp fabric produced in weaving machine comprising fiber are considered.
• the components given in the figure are numbered and the numbers refer to the following:
• melttable thermoplastic yarn A stabilized reinforcing yarn production method comprises the steps of
• thermoplastic yarn used in yarn form in certain distances and thickness depending on the reinforcing yarn:resin (thermoplastic yarn) ratio by weaving between the layers of the reinforcing yarn in weft and warp direction
• the inventive reinforcing textile stabilization method which is developed for composite part production, and enables the resin in form of a thermoplastic yarn used for stabilizing the non-crimp fabric comprising reinforcing yarn to be impregnated into the structure homogenously and deeply; comprises the steps of
• thermoplastic resin in yarn form to be impregnated into the structure by melting in the fabric
• T g glass transition temperature
• thermoplastic yarn used as resin is impregnated between the fibers of the reinforcing yarn by melting the thermoplastic yarn via hot roll, press or infrared heater. If the dry fabric stabilized with thermoplastic yarn will be used for thermoplastic composite production, it is preferred that the thermoplastic yarn to be used for stabilization is same as the resin used as matrix. In use for producing thermoset composite, the thermoplastic yarn used for stabilization is coated with suitable sizing material. Therefore, the thermoset resin used as matrix is compatible with the thermoplastic yarn.
• the polymers used for stabilization process are manufactured from material selected from a group comprising polyamides (such as polyamide 6 (PA6), polyamide 6,6 (PA66), polyphthalamide (PPA) ), polyphenylene sulfide (PPS), polysulfone (PSU) (such as polyethersulfone (PES), poly arylenethersulf one), polyarylenesulfide, fluoropolymer, polyacetal, polycarbonate, styrenic polymer, polyolefins (such as polyethylene (PE), polypropylene (PP)), polyimide (PI), polyetherimide, polyesters preferably polyethylene terephthalate (PET) or polybutylene terephthalate (PBT), polyether ether ket
• the weight of the meltable thermoplastic yarn used for stabilization can change between 10 to 2000 dtex.
• the reinforcing yarn (A) used in producing the non-crimp fabric can be a yarn produced from a material selected from the group comprising glass fiber, carbon fiber, aramid fiber, natural fiber, or a combination thereof.
• non-crimp fabric used in the invention is defined as a system comprised of one or more than one unidirectional fiber layers, and formed by holding these layers together by weaving with a yarn manufactured from thermoplastic polymer. When the angles of the unidirectional layers forming the non-crimp fabrics are considered, the fabrics can be unidirectional, biaxial, triaxial or multiaxial.
• dtex used in the invention is the weight in grams per 10.000 meters yarn.
• the resin used for stabilization being in form of yarn manufactured from thermoplastic fiber enables the ratio of resin/reinforcing fiber in the fabric to be adjusted easily.
• the present invention comprises application of 0-100 bars, preferably in range of 0-40, of pressure on the resin in step of heating of the resin.
• the cooling of the resin penetrating into the fabric is carried out under 0-100 bars of pressure, preferably in range of 1-40 bars of pressure.
• the weight of the thermoplastic resin used for stabilization is maximum 10% of the weight of the yarn manufactured from reinforcing fiber.
• discontinuous or continuous methods can be used.
• the main principle used in both methods is to apply the resin used for stabilizing the non-crimp fabric produced with yarn manufactured from reinforcing yarn in thermoplastic yarn form, and to apply pressure (0-100 bar) at a temperature above softening or melting point, and to enable the resin to impregnate into the reinforcing yarns in this way.
• Cooling process is applied after temperature and pressure is applied for a determined time between 0.01 minutes and 60 minutes. Cooling process can be applied without pressure or under pressure (0-100 bar) depending on the structure of the polymer.
• the cooling temperature is below the glass transition temperature (T g ) of the resin.
• the temperature range that can be used in cooling process is between 25°C and 200°C.
• the applications known in the state of the art cannot provide the resin to be homogenously impregnated into the fibers and cannot provide precise resin distribution.
• the inventive method since the resin is used in yarn form, the resin/reinforcing fiber ratio can be accurately adjusted.
• resin homogenization in amount is provided before starting the process.
• the yarns manufactured from reinforcing fiber (glass, carbon, aramid, natural fiber, etc.) used in dry fabric are applied in single layer or different layers of the fabric, and thus it is possible to use the hybrid structure obtained in this way.
• Two or more types of reinforcing yarns (A) can be used in hybrid fabrics.
• carbon (A), glass (A) and thermoplastic yarn (B) can be used in the same non-crimp fabric.
• dry fabric comprising reinforcing yarn (A) and thermoplastic yarn (B) is produced with weaving machine.
• stabilized textile material can be produced in the same process by using infrared heater right after the weaving process. Therefore, there is no extra process step required during powder or liquid coating applied for conventional thermoplastic stabilization production, and thus the production is carried out faster.
• complex composite parts can easily be manufactured via easy lay-up.
• non-crimp fabrics comprising reinforcing yarn (A) and thermoplastic yarn (B) can be processed in more accurate resin amounts, and they can be processed more easily.
• the fabric kinds that are designed differently, textiles with different mechanical properties can be obtained.
• the composite structure can be varied compatible with the field of use of the end user.
• the inventive fabrics are suitable for being used in wide range of application fields since it allows placing the reinforcing yarn in different axes.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Composite Materials (AREA)
• Mechanical Engineering (AREA)
• Woven Fabrics (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Applications Claiming Priority (2)

Publications (2)

Family

ID=65233900

Family Applications (1)

Country Status (2)

Cited By (1)

Family Cites Families (3)

• 2016
  • 2016-12-12 TR TR2016/18343A patent/TR201618343A2/tr unknown
• 2017
  • 2017-12-11 WO PCT/TR2017/050643 patent/WO2019027385A2/en active Application Filing

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