WO2022218756A1 - Couche textile cousue - Google Patents

Couche textile cousue Download PDF

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Publication number
WO2022218756A1
WO2022218756A1 PCT/EP2022/058967 EP2022058967W WO2022218756A1 WO 2022218756 A1 WO2022218756 A1 WO 2022218756A1 EP 2022058967 W EP2022058967 W EP 2022058967W WO 2022218756 A1 WO2022218756 A1 WO 2022218756A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
fiber
layers
textile
textile layer
Prior art date
Application number
PCT/EP2022/058967
Other languages
German (de)
English (en)
Inventor
Johannes Rehbein
Ronny Wockatz
Original Assignee
Teijin Carbon Europe Gmbh
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 Teijin Carbon Europe Gmbh filed Critical Teijin Carbon Europe Gmbh
Publication of WO2022218756A1 publication Critical patent/WO2022218756A1/fr

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Classifications

    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04BKNITTING
    • D04B21/00Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/14Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
    • D04B21/16Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
    • D04B21/165Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads with yarns stitched through one or more layers or tows, e.g. stitch-bonded fabrics
    • DTEXTILES; PAPER
    • D10INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10BINDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00Details of fabric structure established in the fabric forming process
    • D10B2403/02Cross-sectional features
    • D10B2403/024Fabric incorporating additional compounds
    • D10B2403/0241Fabric incorporating additional compounds enhancing mechanical properties
    • D10B2403/02412Fabric incorporating additional compounds enhancing mechanical properties including several arrays of unbent yarn, e.g. multiaxial fabrics
    • DTEXTILES; PAPER
    • D10INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10BINDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00Industrial
    • D10B2505/02Reinforcing materials; Prepregs

Definitions

  • the invention relates to a sewn textile layer according to claim 1.
  • Stitched textiles are well known.
  • the document EP 2547816 describes a textile layer which was advantageously sewn using a combination of stitch width, stitch length and yarn count.
  • the sewing is designed for diagonally aligned fiber layers.
  • the formula prevents unwanted fiber bundling.
  • bundling is unavoidable to a certain extent, since almost the same reinforcing fibers are fixed in a row of stitches and thus bundled over the entire width of the textile.
  • Textile layers which, for example, consist exclusively of fiber layers with an orientation of 0° and 90° are therefore not provided according to document EP 2547816 and the formula does not take such structures into account.
  • the object of the present invention is to overcome the disadvantages of the prior art, which arise specifically for textiles made up of fiber layers laid exclusively in a 90° direction or textiles made up exclusively of fiber layers laid down in a combination of 90° to the 0° direction and 0° direction.
  • a textile according to claim 1 A textile usually consists of several unidirectional fiber layers. These fiber layers are in turn built up from other layers during production. The following definitions continue to be used for this:
  • Textile layer or textile One layer of the entire sewn multiaxial fabric (Example: 0/90 NCF (Non-Crimp-Fabric) with 536 g/m 2 (grams per square meter))
  • Fiber layer unidirectional layer of the multiaxial non-crimp fabric (example: 90° layer with 268 g/m 2 ), made up of one or more tape layers.
  • the fiber layer can consist of one or more tape layers.
  • the tape layer is made up of a number of spread rovings. The individual rovings are arranged without gaps within the tape layer.
  • a tape layer usually consists of two layers of roving, which are laid on top of each other in an offset manner. Two tape layers of 134 g/m 2 each can together form the basis weight of 268 g/m 2 of this 90° fiber layer of the multiaxial non-crimp fabric.
  • a roving is a bundle, strand or multifilament yarn made of parallel filaments (continuous fibers).
  • To form the tape layer at least two layers are generally produced from a plurality of rovings arranged next to one another. (Example: Each individual roving is spread within the tape layer to approx. 134 g/m 2. Two layers of rovings arranged next to one another are then brought together to form a tape layer)
  • Each fiber layer of the textile layer preferably consists of one tape layer or two or more tape layers laid one on top of the other.
  • the tape layer consists of parallel laid rovings. There are essentially no gaps or spaces between the rovings of a tape layer (no yarn-free areas).
  • the roving layers are laid one on top of the other in an overlapping manner to form the tape layer, preferably with an overlap of 50%.
  • the tap layers to form the fiber layers are preferably also laid down in an overlapping manner, preferably with a 50% overlap for one Fiber layer with a basis weight that is twice as high as that of the tape layers used.
  • the width of the individual tape layers is typically between 100 mm and 700 mm.
  • the tape layers are preferably formed from rovings of multifilament reinforcing fibers.
  • a tape layer can consist of one or more roving layers. As a rule, at least two layers of roving are laid one on top of the other. The rovings typically overlap by 50% of their width in order to form an even, gap-free tape layer. The rovings can be spread or bundled to achieve the desired basis weight.
  • the textile layer has only fiber layers laid down in a 90° direction to the 0° direction (also just 90° fiber layer for short) or only fiber layers laid down in a combination of a 0° direction and a 90° direction.
  • the fiber layers are sewn to form the textile layer with a stitch length in the range from 2.5 mm to 5.5 mm and a sewing thread with 20-35 dtex is used for sewing, the fiber layers having a basis weight in the range from 100 to 400 g/m 2 have.
  • the fiber layers are formed from tape layers, the rovings in the tape layers each having a width in the range from 4 to 32 mm, preferably 6 to 14 mm.
  • a combination of the parameters mentioned in claim 1 can effectively prevent repeated punctures between the rovings of a tape layer when the fiber layers are sewn to form the textile layer. This can result in yarn bundling within the fiber layer and waviness of the adjacent fiber layer can be effectively prevented. All parameters work together synergistically to achieve optimal sewing. This significantly reduced yarn bundling results in a very homogeneous surface quality. In addition to a higher component resilience due to reduced fiber undulation, this leads to a surface quality that has proven to be particularly suitable in the area of visible applications, eg in the automotive sector.
  • Fiber layers that are laid down within the textile layer at an angle of 90° to the 0° direction can have a deviation of +/- 2° to 5° and should still be laid down as a fiber layer - laid down at an angle of 90° to the 0° direction - apply. Fiber layers that are laid down in the 0° direction within the textile layer can have a deviation of +/- 2° to 5° and should still count as a fiber layer - laid down in the 0° direction.
  • the fiber layer laid at an angle of 90° is an outer layer of the textile layer, provided that no other fiber layer (of tape layers) of the textile layer with a different fiber orientation of the rovings (e.g. the multifilament reinforcing fibers) form an outer layer.
  • a textile layer that has a 90° fiber layer as an outer layer can still have a fleece layer that represents the last layer of the textile layer.
  • the filaments of a roving have a better cohesion to each other than to filaments of other rovings, even in the tape layer consisting of many rovings. Accordingly, with regard to transverse strength, the transition area between two adjacent rovings is a weak point in the tape layer. If the puncture holes of the sewing hit exactly this weak point of a 90° layer, there is a greater risk of fiber bundling or even the formation of aisles. It is inevitable that the stitching will occasionally hit these transitional areas as well. However, it is disadvantageous for the textile quality if this happens several times in succession over longer areas of the textile. Surprisingly, it was found that this is the case when the roving width in the textile b is approximately equal to or a multiple of the stitch length s.
  • n RL the number of superimposed layers of multifilament reinforcement yarns (roving layers) in a tape layer
  • Tt is the count of the multifilament reinforcing yarns of the rovings in tex
  • the fiber layers are sewn together with a stitch length in the range from 2.5 mm to 5.5 mm.
  • Stitch lengths that are less than 2.5 mm or greater than 5.5 mm are excluded because they do not lead to a technically satisfactory result in a textile layer with the properties according to claim 1.
  • the fiber layers of the textile layer are preferably sewn together according to the above formula.
  • a textile layer that is exclusively made of fiber layers laid at a 90° angle to the 0° direction or a combination of fiber layers laid down in 0 ° direction and 90 ° direction good drapability can be achieved without layer waviness, which would not be the case with a textile layer without the combination of these parameters.
  • the tape layers are preferably produced from rovings made from carbon fiber yarns, glass fiber or aramid yarns and/or highly drawn ultra-high-molecular-weight polyethylene yarns.
  • the yarns used to produce multiaxial fabrics can be used as sewing or knitting threads.
  • sewing threads are also understood to mean those threads that are not introduced into the textile layer by sewing, but by other stitch-forming textile processes, such as in particular by knitting processes.
  • the stitches, via which the sewing threads connect the fiber layers of the textile layer to one another can be, for example, tricot weaves or fringed weaves. A tricot weave or a combination of tricot and fringed weave is preferred for multiaxial non-crimp fabrics with a 0°/90° layer structure.
  • the textile layer is preferably sewn in tricot and/or tricot loop style.
  • the sewing threads are multifilament yarns. Sewing threads can be used that melt during a later resin injection (to produce a fiber composite component), for example above the resin injection temperature but below the curing temperature of the resin used.
  • the yarns can also be meltable at the curing temperature itself.
  • the sewing threads can also be those that are in the matrix resin, for example during the injection or even during it curing are solvable. Such sewing threads or sewing yarns are described, for example, in DE 19925588, EP 1 057605 or US Pat. No. 6,890,476, to the relevant disclosure of which reference is expressly made.
  • the sewing threads are preferably made of polyamide, polyaramide, polyester, polyacrylic, polyhydroxyether or of copolymers of these polymers.
  • the sewing threads are particularly preferably multifilament yarns made from polyester, polyamide or polyhydroxyether or from copolymers of these polymers.
  • the sewing threads advantageously have an elongation at break of >50% at room temperature.
  • the high elongation at break makes it possible to achieve improved drapability of the textile layer according to the invention, as a result of which more complex structures or more complex components can also be realized without creases.
  • the sewing threads have a titre in the range from 20 to 35 dtex, particularly preferably from 25 to 33 dtex.
  • drapability it has been shown that in particular the stability to pressure stresses is significantly improved if the titre of the sewing threads is in the stated range. Both the improvement in the drapability and the improved pressure application are attributed to the fact that when such sewing threads are used, the thread pattern of the individual fiber layers is significantly more even, since the stitching holes are smaller.
  • the filaments of the multifilament reinforcement fibers show a more linear course than is the case with a textile layer of the prior art, although the fiber layers are only in a 90° orientation in the textile layer or only a combination of fiber layers in a 90° and 0° direction in of the textile layer.
  • the carbon fiber yarns preferably have a strength of at least 5000 MPa, measured according to JIS-R- 7608 and a tensile modulus of at least 260 GPa, measured according to JIS-R-7608. Furthermore, in one embodiment, the carbon fiber yarns preferably have a strength of at least 4500 MPa, measured according to JIS-R-7608, and a tensile modulus of at least 240 GPa, measured according to JIS -R- 7608 on.
  • the textile layer has at least one fleece layer.
  • the fleece layer can be arranged between the fiber layers and/or be provided on one or both outer sides of the textile layer.
  • the at least one fleece layer preferably has a weight per unit area in the range from 3 to 25 g/m 2 .
  • the basis weight of the fleece layer is particularly preferably 4 to 6 g/m 2 .
  • the at least one fleece preferably has a binder material in particle form, with the particle size of the binder material being between 50 and 160 ⁇ m. It is also preferred if the at least one fleece is formed from thermoplastic polymer material.
  • the textile layer can have different fleece layers that differ from one another in terms of their weight per unit area and/or binder materials and/or material starting materials. The use of different components to achieve differentiated melting ranges - e.g. as a so-called hybrid fleece - represents a potential embodiment.
  • the fiber layers preferably each have a weight per unit area of at least 60 g/m 2 , more preferably 150 g/m 2 , particularly preferably at least 190 g/m 2 .
  • the basis weight of a fiber layer can be 120 g/m 2 , 134 g/m 2 , 190 g/m 2 , 194 g/m 2 , 240 g/m 2 , 268 g/m 2 or 360 g/m 2 .
  • a combination of fiber layers with the same basis weight or with different basis weights can be combined in one textile layer.
  • the textile layer can be made up of two fiber layers, one fiber layer having a basis weight of 360 g/m 2 and the other 120 g/m 2 .
  • the fiber layer with a basis weight of 360 g/m 2 can be a fiber layer in the 0° direction of the textile layer or a fiber layer laid down in a 90° to the 0° direction.
  • the fiber layer with a basis weight of 120 g/m 2 can have been laid in the 0° direction or in 90° to the 0° direction in the textile layer.
  • the textile layer consists entirely of fiber layers laid down at an angle of 90° to the 0° direction of the textile layer.
  • the 0° direction is the free position direction of the textile layer.
  • the textile layer has at least one fiber layer in the 0° direction in addition to at least one fiber layer in the 90° direction.
  • the textile layer consists of only two fiber layers and optionally one or more non-woven layer(s), one fiber layer being laid in the 0° direction and the other fiber layer in 90° to the 0° direction within the textile layer.
  • a further object of the present invention relates to an intermediate product which has at least two textile layers of the type described above.
  • the at least two textile layers are preferably at least partially connected to one another within the intermediate product.
  • a partial connection is to be understood here when the two textile layers are only connected to one another at discrete points (and therefore not over the entire surface).
  • the connection should be such that the textile layers form a unit permanently or temporarily and, for example, cannot be displaced in relation to one another.
  • a partial connection has the advantage that the drapability of the intermediate product formed in this way is still very good (no stiffening), but slipping of the individual textile layers in the intermediate product, for example during resin infiltration, is avoided. Flowing also significantly improves the handling of the intermediate product.
  • the textile layers are partially connected within the intermediate product by means of gluing.
  • an outside of a textile layer can have a fleece layer that comprises a powdered, polymeric binder material.
  • the intermediate product can be heated for a short time so that the polymeric binder melts and there is partial adhesion between adjacent textile layers.
  • the strength of the bond can advantageously be varied by the amount, distribution and type (material and/or particle size) of the binder material and the number and arrangement of fleece layers constructed in this way in the textile layers.
  • Another object of the present invention is a composite material or composite that has at least one intermediate product of the type described above and a matrix material.
  • the required matrix portion is introduced into the intermediate product via infusion or injection, also using a vacuum.
  • the matrix material is cured at generally elevated temperatures and pressures to form the finished composite material (component).
  • LM method liquid molding
  • RVARTM Vacuum Assisted Resin Transfer Molding
  • RRI Resin Film Infusion
  • LRI Liquid Resin Infusion
  • RIFT Resin Infusion Flexible Tooling
  • a plurality of textile layers (as described above) can be laid one on top of the other in several layers without matrix material in a form adapted to the component contour until the desired thickness is reached.
  • the composite can preferably be used for aerospace, automobiles and/or for the production of lightweight components.
  • the textile layer as described above
  • the textile layer has particularly good drapability and a very homogeneous surface, and so does so Composites with, for example, curved contours can be produced more easily and with excellent surface quality.
  • a textile layer is made up of two fiber layers.
  • Carbon fibers TenaxTM-E ITS55 E23 24K with 1600 tex were used as multifilament reinforcement fibers for the tape layers.
  • the basis weight of each fiber layer is 268 g/m 2 (FAW).
  • the basis weight of the tape layers is therefore 134 g/m 2 .
  • the width of the rovings in mm (b) within the fiber layer is 11.94 mm.
  • one fiber layer was laid on top of the other in the 0° direction and one fiber layer in the 90° direction (to the 0° direction). Both fiber layers were connected to each other by sewing.
  • a co-polyamide thread with 33 dtex was used as the sewing thread, the sewing was done in the 0° direction with a tricot 3.6 mm binding, with the stitching taking place through the 90° layer.
  • Example 2 The structure of the textile layer and the material for the sewing is selected as in example 1, but the carbon fiber yarn Tenax TM -E HTS45 E23 12K with 800tex was used as the multifilament reinforcing yarn and the individual fiber layers had a basis weight of 194 g/m 2 .
  • the textile layer is consequently made up of two fiber layers.
  • the basis weight of the tape layers is 97 g/m 2 .
  • the width of the rovings in mm (b) within the fiber layer is 8.25 mm.
  • a fiber layer in the 0° direction and a fiber layer in the 90° direction (to the 0° direction) were laid one on top of the other. Both fiber layers were connected to each other by sewing.
  • a co-polyamide thread with 33 dtex was used as the sewing thread, the sewing was done in the 0° direction with a tricot 3.6 mm binding, with the stitching taking place through the 90° layer.
  • the sewing took place under the condition:
  • FIG. 1 schematically shows the side view of a cross section of a textile layer not according to the invention
  • FIG. 2 schematically shows two fiber layers which are sewn together to form a textile layer, the sewing not taking place according to the invention.
  • FIG. 3 schematically shows two fiber layers which are sewn together to form a textile layer, the sewing being carried out according to the invention.
  • Figure 4 shows a fabric ply with a stitch according to the invention and a fabric ply with a stitch outside the claimed invention.
  • a textile layer 1 is shown schematically in Figure 1, which has a fiber layer 2 in the 0° direction 6 (direction 6 not shown in Figure 1) and a fiber layer 2 ' in the 90° direction 7 perpendicular to the 0° direction 6 (direction 7 not shown in Figure 1).
  • FIG. 1 only shows the fiber layer 2 ′ in the 90° direction 7 schematically, that it consists of a single tape layer, which in turn is made up of two roving layers 3,3 ′ with rovings 4, 4 ′ .
  • the tape layers each consist of rovings 4 and 4', which are arranged offset to one another one above the other within the tape layer. Within each tape layer, the rovings 4, 4 ' lie parallel next to one another without yarn-free areas being present.
  • the fiber layers 2, 2 ' are sewn together by means of a sewing thread 5.
  • the sewing takes place in the 0° direction 6.
  • Figure 1 is a stitch length s of the sewing of the width b of the rovings 4, 4 ' .
  • the cohesion of the roving layers 3, 3 ' is low, so that the risk of fiber bundling is particularly high.
  • the width b of the rovings 4, 4 ' in the 90° position 2 ' is therefore different from integral multiples of the stitch length s.
  • the stitch length s is consequently substantially different from half, a third, a quarter etc. of the width b of the rovings 4, 4 ' .
  • the stitch length s should not be 1.5 times or 2.5 times either.
  • FIG. 2 schematically shows the view from below onto a 90° fiber layer 2 ′ of a textile layer not according to the invention.
  • the stitch length s is 1/2 of the width b of the rovings 4.4 ′ , as a result of which a yarn bundling 8 occurs within the fiber layer 2 ′ in a 90° direction 7 .
  • the sewing took place in the 0° direction 6, which was also the production direction.
  • FIG. 3 shows a schematic view of a 90° fiber layer 2 ′ of a textile layer according to the invention from below.
  • the left part of the figure shows a textile layer with a stitching according to the conditions of claim 1.
  • Within the textile layer there are no gaps in the fiber layers due to bundling of the rovings, which means that there are no yarn-free areas in the later material (which has the textile layer). are formed.
  • a textile layer is shown, which was formed by means of sewing outside the parameters of the invention. This is where the rovings shift within the fiber layer, so that yarn-free areas within the fiber layers are formed by the sewing. In the later material (comprising the textile layer) this creates areas without fiber reinforcement, which reduces the mechanical properties of the material and makes them unpredictable.

Abstract

L'invention concerne une couche textile optimisée comprenant des couches de fibres qui sont cousues et présentent des propriétés prédéfinies. Cela permet de réduire l'ondulation de couche des couches textiles avec des couches de fibres dans la direction 0° et dans la direction de 90°. L'invention concerne également un produit intermédiaire constitué au moins de deux couches textiles selon l'invention et un composite produit à partir d'au moins un produit intermédiaire.
PCT/EP2022/058967 2021-04-14 2022-04-05 Couche textile cousue WO2022218756A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP21168373.5 2021-04-14
EP21168373 2021-04-14

Publications (1)

Publication Number Publication Date
WO2022218756A1 true WO2022218756A1 (fr) 2022-10-20

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PCT/EP2022/058967 WO2022218756A1 (fr) 2021-04-14 2022-04-05 Couche textile cousue

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1057605A1 (fr) 1999-06-04 2000-12-06 DLR Deutsches Zentrum für Luft- und Raumfahrt e.V. Fil pour lier les fibres d'un materiau composite et procédé de fabrication
EP1174533A1 (fr) * 2000-02-28 2002-01-23 Toray Industries, Inc. Materiau support renforcateur pique de facon multiaxiale, fil plastique a fibre renforcee, et procede de preparation correspondant
WO2010067003A1 (fr) * 2008-12-09 2010-06-17 Hexcel Reinforcements Nouveau materiau intermediaire destine a limiter les microfissurations de pieces composites
WO2011113752A1 (fr) * 2010-03-18 2011-09-22 Toho Tenax Europe Gmbh Tissus multiaxiaux présentant des non-tissés polymères
EP2547816A1 (fr) 2010-03-18 2013-01-23 Toho Tenax Europe GmbH Tissu multiaxial cousu

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1057605A1 (fr) 1999-06-04 2000-12-06 DLR Deutsches Zentrum für Luft- und Raumfahrt e.V. Fil pour lier les fibres d'un materiau composite et procédé de fabrication
DE19925588A1 (de) 1999-06-04 2000-12-07 Deutsch Zentr Luft & Raumfahrt Faden zur Verbindung von Fasern eines Faserhalbzeuges sowie Faserhalbzeug, und Verfahren zur Herstellung von Faserverbundwerkstoffen
US6890476B2 (en) 1999-06-04 2005-05-10 Saertex Wagener Gmbh & Co. Kg Fiber-reinforced composites and method for the production thereof
EP1174533A1 (fr) * 2000-02-28 2002-01-23 Toray Industries, Inc. Materiau support renforcateur pique de facon multiaxiale, fil plastique a fibre renforcee, et procede de preparation correspondant
WO2010067003A1 (fr) * 2008-12-09 2010-06-17 Hexcel Reinforcements Nouveau materiau intermediaire destine a limiter les microfissurations de pieces composites
WO2011113752A1 (fr) * 2010-03-18 2011-09-22 Toho Tenax Europe Gmbh Tissus multiaxiaux présentant des non-tissés polymères
EP2547816A1 (fr) 2010-03-18 2013-01-23 Toho Tenax Europe GmbH Tissu multiaxial cousu

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