WO2023170150A1

WO2023170150A1 - Fibre composite material made of at least one tape

Info

Publication number: WO2023170150A1
Application number: PCT/EP2023/055896
Authority: WO
Inventors: Andreas Flachenecker; Christian Vieth; Arkadiusz MATYJA; Daniel HEHN
Original assignee: Php Fibers Gmbh
Priority date: 2022-03-10
Filing date: 2023-03-08
Publication date: 2023-09-14

Abstract

The invention relates to a fibre composite material which is made of at least one tape having a width of 30 mm. The tape comprises at least two hybrid rovings, wherein each hybrid roving comprises at least one layer of reinforcing fibres and at least two layers of thermoplastic fibres. The at least two hybrid rovings are arranged in the tape next to one another and so as to abut one another, without overlapping, transversely to the main propagation direction of the reinforcing fibres. Each hybrid roving has a width transverse to the orientation of the fibre of at least 15 mm and the reinforcing fibres of the hybrid roving are not twisted in the fibre composite material. The invention also relates to a method for producing the fibre composite material, and to the tape itself.

Description

Fiber composite material made of at least one tape

Description:

The invention relates to a fiber composite material made from at least one tape made from at least two hybrid rovings. The invention further relates to a method for producing the fiber composite material and a tape from hybrid rovings.

Hybrid rovings are already known. Such hybrid rovings are described, for example, in document EP 3638492. However, fiber composite materials made from these hybrid rovings often have mechanical properties that are not homogeneous within the fiber composite material. Furthermore, the production of the fiber composite materials from the known hybrid rovings is complex because a large number of hybrid rovings have to be unrolled and processed via creels for production. Document DE 10 2014 019 220 D1 describes a method for producing a bath-shaped semi-finished product. Here, for example, matrix fiber bundles are spread out together with reinforcing fiber bundles and placed on top of each other. The width of the fiber bundles should be from 6 mm to a maximum of 16 mm and in a three-layer structure, adjacent fiber bundles overlap one another.

The object of the present invention was therefore to provide a fiber composite material made of at least one tape, whereby the at least a tape is formed from at least two hybrid rovings, which means that the fiber composite material is easier to produce and its mechanical properties are more homogeneous than in comparison to the prior art.

The task is solved with a fiber composite material according to claim 1.

In the fiber composite material according to the invention, the fiber composite material has at least one tape, the tape being constructed from at least two hybrid rovings. Each of the hybrid rovings consists of at least one layer of reinforcing fibers arranged directly between at least two layers of thermoplastic fibers. The layer of reinforcing fibers and the layers of thermoplastic fibers of each hybrid roving have a width transverse to the main direction of propagation of the reinforcing fibers that is more than 15 mm. At least two hybrid rovings are arranged next to each other and adjacent to each other without overlapping, transversely to the main direction of propagation of the reinforcing fibers, and thus form at least one tape. The at least one tape has a width transverse to the main direction of propagation of the reinforcing fibers of at least 30 mm. At least the reinforcing fibers are present within the fiber composite material without twisting in the fiber composite material.

A hybrid roving is to be understood as meaning an at least three-layer structure made of fiber layers, with the different fiber layers within the hybrid roving arranged one on top of the other essentially perpendicular to the main direction of propagation of the fibers (reinforcing fibers).

At least two hybrid rovings are used to form a tape. The hybrid rovings are arranged in the tape in such a way that the fiber layers are of the same type and the same layer of the different hybrid rovings next to each other, adjacent to each other (Figure 4). This means, for example, that the first layer of the thermoplastic fibers of the first hybrid roving lie next to each other without overlap, adjacent to the first layer of the thermoplastic fibers of the second hybrid roving in the tape. The reinforcing fibers of the first hybrid roving lying between the first and the second layer of thermoplastic fibers are also arranged next to each other without overlap, adjacent to the layer of reinforcing fibers of the second hybrid roving. Accordingly, the second layers of thermoplastic fibers of the first and second hybrid rovings lie next to each other without overlapping, against each other. This creates a tape that has a width transverse to the main direction of propagation of the reinforcing fibers of at least 30 mm, but in which the fiber distribution is very even. The lack of overlap areas of the same fiber types advantageously avoids localized areas with a higher fiber concentration, which can influence the mechanical properties of the later fiber composite material. Furthermore, the use of tapes for producing the fiber composite material with a width transverse to the main direction of propagation of the reinforcing fibers of at least 30 mm enables the fiber composite material to be produced from as few coils as possible (with tape material), which reduces the set-up time for production. For example, only 10 spools need to be filled with tape material to produce the fiber composite material, instead of 20 or more spools, even though the later fiber composite material should have the same dimensions.

The fiber composite material can be formed from a plurality of tapes, where each tape can be formed from a plurality of hybrid rovings.

In one embodiment, the at least one tape is formed from two spread glass fiber rovings (reinforcing fibers) and four spread ones thermoplastic fiber rovings (which together form two hybrid rovings), each of the fiber layers having a width measured transversely to the main direction of propagation of the reinforcing fibers of approximately 15 mm. In the tape, the layer of reinforcing fibers and the layers of thermoplastic fibers then have a width of 30 mm measured transversely to the main direction of propagation of the reinforcing fibers.

When producing the fiber composite material, an already produced tape is preferably unwound from rolls or spools and processed into the fiber composite material. In another embodiment, however, the tape can also be formed during the production of the fiber composite material in an upstream step by assembling hybrid rovings. For example, a plurality of hybrid rovings can be spread in a first process step and laid down accordingly to form a tape, with the at least one tape then being joined together in a pultrusion process to form the fiber composite material.

All three layers of each tape are preferably subjected to a pressure of at least 2 bar and heat during the production of the fiber composite material or before the production of the fiber composite material (for example during the production of the tape), so that the thermoplastic fibers melt into a thermoplastic material which forms the reinforcing fibers encloses. The layer of enclosed reinforcing fibers is then cooled, preferably under pressure, until the thermoplastic material is no longer flowable. This makes it advantageously possible to produce the tape without overlapping areas and still obtain a manageable (layer-proof) tape.

In one embodiment, all three layers of each hybrid roving are preferably made during the production of the fiber composite material or before Production of the fiber composite material (for example in the production of the tape) is subjected to a pressure of at least 2 bar and heat, so that the thermoplastic fibers melt into a thermoplastic material that encloses the reinforcing fibers. The layer of enclosed reinforcing fibers is then cooled, preferably under pressure, until the thermoplastic material is no longer flowable.

In the following, the layers made of reinforcing fibers or thermoplastic fibers are also referred to as fiber layers. Furthermore, the at least one tape can also be referred to as tapes.

A fiber is an endless or length-limited structure whose width is negligibly small in relation to its length. Both endless fibers (continuous fibers) and staple fibers or hollow fibers should be understood as fibers. The fibers can be multifilament fibers or monofilament fibers. The fiber can also be present as a core-sheath fiber. Furthermore, the fibers can be present, for example, in the form of a chamois (for example multifilament yarn or ribbon yarn).

A width of the fiber layers in hybrid roving transverse to the main direction of propagation (or also called fiber orientation) of the reinforcing fibers means that the width is measured in one plane of the reinforcing fiber layer but at an angle of approximately 90° to the main extent of the fiber. Correspondingly, a width of the tape transverse to the main direction of propagation (or also called fiber orientation) means that the width is measured in a plane of the reinforcing fiber layer, but at an angle of approximately 90° to the main extension of the fiber. According to the invention, the at least one tape, constructed from at least two hybrid rovings lying side by side without overlap, has a width that was previously not known for such tapes. As a result, the fiber composite material can be produced from a smaller number of hybrid rovings and, according to the invention, at least the reinforcing fibers within the fiber composite material are present within the fiber composite material without twisting. Advantageously, a uniform fiber alignment of the reinforcing fibers within the fiber composite material can be obtained and, as a result, homogeneous, high mechanical properties of the fiber composite material. For example, the production of a fiber composite material can be carried out by unwinding and joining (for example under pressure and heat) a plurality of hybrid rovings, with a large number of hybrid rovings - as previously known from the prior art - the hybrid rovings be twisted together when being put together. The more hybrid rovings are required to produce the fiber composite material, the greater the number of hybrid rovings that have a twist. When producing the fiber composite material according to the invention, a smaller number of hybrid rovings can advantageously be used than was previously usual. By combining at least two hybrid rovings into at least one tape, the twisting of the reinforcing fibers during the production of the fiber composite material is also advantageously prevented. Furthermore, the process for producing a fiber composite material is significantly simplified with the use of a few, wide tapes, since, for example, the assembly time and the set-up time in the manufacturing process can be shortened. If the fiber composite material is created, for example, by unwinding and assembling tape rolls, fewer rolls need to be loaded at the beginning of the manufacturing process and may need to be replaced later in the process. Advantageously, the manufacturing process of the fiber composite material is faster and requires fewer or no interruptions in production. Hybrid roving is to be understood as meaning a material that is formed from at least two different starting materials, with the starting materials each being used as roving in hybrid roving. A roving is a bundle, strand or multifilament yarn made of parallel filaments. A fiber layer of the hybrid roving is formed from a fiber roving.

A tape has at least two hybrid rovings. Each hybrid roving has splayed fiber rovings that form the layers of thermoplastic fibers and the layer of reinforcing fibers. The hybrid roving can also have a plurality of thermoplastic fiber layers and layers of reinforcing fibers, which are then arranged one above the other in the hybrid roving (Figure 2). In a tape, the at least one fiber layer of reinforcing fibers can be formed from a plurality of rovings made of reinforcing fibers, which lie next to each other (and also on top of each other). Likewise, each thermoplastic fiber layer can be formed from a plurality of thermoplastic fiber rovings. The number of rovings used in the fiber layer made of reinforcing fibers can be the same or different to the number of rovings for the fiber layer made of thermoplastic fibers, depending on how the tape is to be constructed.

Preferably, all hybrid rovings for constructing the tape are constructed the same and therefore have the same number of thermoplastic fiber layers and fiber layers made of reinforcing fibers.

In one embodiment, the at least one tape has a width, measured transversely to the main direction of propagation of the reinforcing fibers, which is greater than its thickness, measured in the direction of the first fiber layer made of thermoplastic fibers to the second fiber layer made of thermoplastic fibers. Preferably, the width of the tape is 20 to 25 times larger perpendicular to the fiber orientation as the thickness of the tape, measured in the direction of the first fiber layer made of thermoplastic fibers to the second fiber layer made of thermoplastic fibers. Each hybrid roving preferably also has a width, measured transversely to the main direction of propagation of the reinforcing fibers, which is larger (preferably 20 to 25 times) than its thickness, measured in the direction of the first fiber layer made of thermoplastic fibers to the second fiber layer made of thermoplastic fibers.

In one embodiment, during the production of the fiber composite material, the thermoplastic fibers in the hybrid rovings - or in at least one tape - melt and the reinforcing fibers are preferably completely surrounded by the thermoplastic material of the thermoplastic fibers, preferably without an edge region made only of thermoplastic material. With regard to the structure and production of the hybrid roving, reference is made to the disclosure on the ribbon-shaped composite material in EP 3638492, the content of which is intended to become part of this disclosure.

In hybrid roving, the fiber layer made of reinforcing fibers is preferably in direct contact with the two fiber layers made of thermoplastic fibers. Even in at least one tape, the fiber layer made of reinforcing fibers is preferably in direct contact with the two fiber layers made of thermoplastic fibers. The direct arrangement of the at least one layer of reinforcing fibers between the two layers of thermoplastic fibers means that there is no longer any further layer made of a different material between the reinforcing fibers and the layers of thermoplastic fibers.

The thermoplastic fibers can be present in the hybrid rovings, or in at least one tape, as filaments, staple fibers, multifilament fibers, games, monofilaments or ribbon games made of thermoplastic material. Any material whose melting range or melting point is not greater than 500°C, more preferably not greater than 350°C, is suitable as a thermoplastic material for the thermoplastic fibers.

The preferred thermoplastic fibers used are fibers made from aliphatic and partially aromatic polyamides, polyoxymethylene (POM), polyesters, PEEK, PEN, POK, PP, PE or PVC or mixtures thereof. The thermoplastic fibers can have thixotropic additives.

Fumed silica, Luvotix HAT, Luvotix AB, Luvotix EAB, Luvotix P 100 -15, BYK-405, BYK-420 or BYK-425 are preferably used as thixotropic additives.

In one embodiment of the hybrid roving (or the at least one tape), glass fiber (roving), carbon fiber (tow), basalt fiber, ceramic fiber, viscose fiber, metal fiber, aramid fiber or natural fiber or mixtures of the fibers mentioned are used as reinforcing fibers for the fiber layer made of reinforcing fibers. Preferably, the at least one fiber layer consists of reinforcing fibers from approximately 60 to 100%, more preferably from 80 to 95%, of one of the fibers mentioned or a mixture of the fibers mentioned.

Glass fiber is particularly preferably used as the reinforcing fiber, the glass fiber preferably having a fineness of 1200 to 2400 tex.

Preferably, a fiber layer made of thermoplastic fibers consists of at least one layer, preferably two layers, of thermoplastic multifilament yarns, which are arranged unidirectionally and one above the other in hybrid roving. Preferably this also points at least one tape has two layers of thermoplastic multifilament yarns, which are arranged unidirectionally and one above the other.

The at least one fiber layer of reinforcing fibers in hybrid roving preferably consists of a layer of unidirectionally arranged reinforcing fibers. Preferably, the reinforcing fibers within the fiber layer made of reinforcing fibers in hybrid roving lie next to one another and against one another without overlap.

Preferably, the width of the at least one fiber layer made of reinforcing fibers and the at least two fiber layers made of thermoplastic fibers in hybrid roving transverse to the main direction of propagation of the reinforcing fibers is more than 30 mm, more than 50 mm, more than 100 mm, more than 250 mm, more than 500 mm or more than 600 mm.

In one embodiment, the at least one tape has at least one fiber layer made of reinforcing fibers and at least two fiber layers made of thermoplastic fibers. Preferably, the width of the at least one fiber layer made of reinforcing fibers and the at least two fiber layers made of thermoplastic fibers in at least one tape transverse to the main direction of propagation of the reinforcing fibers is more than 30 mm, more than 50 mm, more than 100 mm, more than 250 mm, more than 500 mm or more than 600 mm.

In one embodiment, the fiber composite material is formed from hybrid rovings with a plurality of fiber layers made of reinforcing fibers, the reinforcing fibers being arranged one above the other in the hybrid roving without offset or with an offset at least in partial areas perpendicular to the main direction of propagation of the reinforcing fibers. In one embodiment, the fiber composite material is formed from at least two tapes, the tapes being arranged one above the other in the fiber composite material without offset or with an offset at least in partial areas perpendicular to the main direction of propagation of the reinforcing fibers.

In one embodiment, the basis weight within the fiber layer of reinforcing fibers and/or within the fiber layers of thermoplastic fibers in each of the at least two hybrid rovings and/or in the at least one tape is constant. Constant means that the basis weight within the fiber layer varies by less than 5%.

Preferably, each of the at least two hybrid rovings and/or the at least one tape has a temporary binder. Thermoplastic dispersions, such as polypropylene in water, are suitable as temporary binders, the proportion of binder to the fiber proportion of the hybrid rovings and/or the at least one tape being in the range from 0.3 to 10% by weight, preferably 3% by weight. is based on the total fiber content of the hybrid roving or the at least one tape. The binder is a temporary binder if it is removed from the hybrid roving and/or the at least one tape during production or before the production of the fiber composite material or is later dissolved in a matrix material of the fiber composite material. For example, the binder can be evaporated using heat before the hybrid rovings are assembled to form the at least one tape. In another embodiment, the binder is only evaporated using heat during the production of the fiber composite material. The temporary binding agent can advantageously reinforce a temporary bond of the different fiber layers within each hybrid roving, so that the hybrid rovings become easier to handle. Furthermore, the temporary binder also temporarily binds the different fiber layers of the different hybrid rovings in at least one tape reinforced. This makes it even easier to form at least one tape without overlapping fiber layers from different hybrid rovings.

In one embodiment, the temporary binder acts as an adhesion promoter in the later fiber composite material. The binder in the hybrid roving preferably binds the different fiber layers together, so that the manageability of the hybrid roving is improved and then ensures better adhesion in the fiber composite material between the material of the hybrid roving and the additional matrix material that is used to produce the fiber composite material the hybrid rovings are used. The binder preferably binds the different fiber layers together in the at least one tape, so that the handling of the at least one tape is improved and then ensures better adhesion in the fiber composite material between the material of the at least one tape and the additional matrix material that is additionally used to produce the fiber composite material becomes.

Preferably the temporary binder is a pressure-sensitive adhesive. In the present application, a pressure-sensitive adhesive is understood to mean materials that have a high tack strength (also known to those skilled in the art as “tack”), which means that they form adhesive bonds with objects that touch the material in question in a very short time. Possible pressure-sensitive adhesives are polymers or copolymers based on acrylates, namely based on 2-ethylhexl acrylate, isoamyl acrylate, hydroxymethacrylate, isooctyl acrylate, acrylic acid, methyl methacrylate or butyl acrylate. The polymers or copolymers used as pressure-sensitive adhesives can also contain styrene, natural rubber, polyterpene resin, polyisoprene, styrene-butadiene rubber, styrene-butadiene rubber, isobutene-isoprene rubber, acrylonitrile-butadiene rubber, chloroprene rubber, polyvinyl acetate or polydiphenyldisiloxane. In one embodiment, the pressure-sensitive adhesive contains swellable acrylate beads. In one embodiment, the pressure-sensitive adhesive contains a Solvent or swelling agent, such as water, an alcohol such as ethanol, methanol, 1-propanol or 2-propanol, a ketone such as acetone or methyl ethyl ketone or an alkane such as n-hexane, n-heptane or petroleum ether. In one embodiment, the component added as a pressure-sensitive adhesive retains its adhesive strength even after heat treatment of the hybrid roving at, for example, 180 ° C. In one embodiment, the pressure-sensitive adhesive is such that it loses its sticky properties over time, for example through the action of light, atmospheric oxygen or through the evaporation of a solvent or swelling agent.

In one embodiment, the amount and type of pressure-sensitive adhesive are selected so that the resulting adhesive bond can be released again by applying a force of approximately 0.01 mN/tex. In this context, approximately means an upward and downward deviation of 50% each.

Another subject of the present invention relates to the fiber composite material. Comments on the hybrid rovings and the at least one tape apply (if appropriate) to the fiber composite material, which is to be produced from at least two hybrid rovings - in at least one tape. The layer of reinforcing fibers of different hybrid rovings are adjacent to one another within the at least one tape transversely to the main direction of propagation of the reinforcing fibers without adhesion and without overlapping, lying next to one another. Preferably, the layers of thermoplastic fibers of different hybrid rovings within the at least one tape are adjacent to one another, adjoining one another, without adhesion and without overlap, transversely to the main direction of propagation of the reinforcing fibers.

Preferably, the fiber composite material is formed from less than 400, preferably less than 300, preferably less than 250, preferably less than 100, preferably less than or equal to 10 hybrid rovings. Preferably, the fiber composite material is made of less than 400, preferably less than 300, preferably less than 200, preferably less than 250, preferably less than 150, preferably less than 125, preferably less than 100, preferably less than 50, preferably less or equal to 10, or less or equal to 5 tapes formed. Each of these tapes preferably has three or more hybrid rovings.

The fiber composite material is preferably made exclusively from a type of hybrid roving, so that all hybrid rovings have the same structure and contain the same material.

The fiber composite material is preferably made exclusively from a type of tape, so that all tapes have the same structure and contain the same material.

The fiber composite material preferably has a homogeneous fiber distribution in the thickness and/or width direction. A homogeneous fiber distribution means that the fiber distribution of the reinforcing fibers within the fiber composite material varies by less than 5%. This advantageously results in a fiber composite material which has no reinforcing fiber-free areas made only of matrix material. This advantageously makes the mechanical properties of the fiber composite material particularly easy to predict.

In one embodiment, the fiber composite material is a pultrudate. A pultrudate is to be understood as meaning a fiber composite material that was formed from at least one tape in a pultrusion process, the at least one tape being formed from at least two hybrid rovings. In one embodiment, the hybrid rovings are made of one via fiber guides multi-story coil storage is guided and spread and joined together to form at least one tape, whereby the fiber layers of the hybrid rovings are next to each other without overlap, lying against one another in the tape, transversely to the main direction of propagation of the reinforcing fibers. At least one tape is fed into a hot pultrusion tool. In this tool, the thermoplastic fibers melt and form a matrix. The additional addition of matrix material to produce the pultrudate is not necessary when using hybrid rovings. The fibers can pass through several preforming stations so that they are formed into the desired pultrudate shape.

Preferably the pultrudate has a rod shape, the rod shape being solid and having a diameter of at least 2 mm.

In one embodiment, the surface of the pultrudate may have a structure with a predetermined thickness. For example, the pultrudate can have a surface similar to that of steel reinforcing bars in concrete construction.

Preferably the pultrudate has a flat profile shape (rectangular), which shape is solid and has a thickness of at least 0.2 mm and a width of at least 6 mm.

Another subject of the present invention relates to a method for producing the fiber composite material - as described above. In this respect, the statements made above also apply to the manufacturing process.

In the manufacturing process, 10, not more than 10 or more than 10 hybrid roving^) are unwound and assembled into at least one tape, with the at least one tape being processed into the fiber composite material. Each of the hybrid rovings has a width of at least 15 mm across Fiber alignment of the hybrid roving and at least the reinforcing fibers are joined together without twisting to form the fiber composite material. Within the at least one tape, the hybrid rovings lie next to each other without overlapping, transverse to the main direction of propagation of the reinforcing fibers.

In the manufacturing process, 10, not more than 10 or more than 10 tapes can also be unwound and processed into the fiber composite material. In the manufacturing process, 5, not more than 5 or more than 5 tapes can also be unwound and processed into the fiber composite material, with each tape being formed from at least two hybrid rovings.

Preferably, in the manufacturing process of the fiber composite material, no more than 300 hybrid rovings are used for production, each hybrid roving having a width transverse to the fiber orientation of more than 15 mm and / or the fiber composite material having a width transverse to the fiber orientation of more than 30 mm, preferably more than 50 mm.

By using at least one tape by joining at least two hybrid rovings, the risk of fiber twisting during the production of the fiber composite material is significantly reduced. This increases the uniformity of the fiber composite material. In addition, the friction and pressure fluctuations in the consolidation tool are reduced because only relatively few tapes have to be used for production. As already described above, this can advantageously improve the mechanical properties of the fiber composite material.

In one embodiment, the hybrid rovings are first combined into a tape in a separate work step. The rolls with the tape will be then rolled up and can be stored. To produce the fiber composite material, the rolls (or spools) with the tape are then unrolled and processed into the fiber composite material. However, the at least one tape can also be produced as a temporary intermediate product after the hybrid rovings have been unrolled and before the fiber composite material is produced, without the at least one tape being wound up (stored and later processed).

The hybrid rovings are preferably joined together to form at least one tape so that the thermoplastic fibers of the hybrid rovings are also twist-free. However, at the latest during the manufacturing process of the fiber composite material, the thermoplastic fibers are completely melted, so that fiber orientation of the thermoplastic fibers can no longer be determined in the fiber composite material. Here, the thermoplastic fiber material encloses the reinforcing fibers and forms the matrix of the fiber composite material, or forms a connection with a supplied matrix material.

In one embodiment, the fiber composite material is produced from a plurality of tapes, with all tapes having the same structure (same material, same number of fibers, same number of layers).

In another embodiment, the fiber composite material is made from a plurality of tapes, with at least two types of tapes being used. The at least two types of tapes differ from each other in the type of material used for the fibers, the number of fibers within the different layers, the fiber spread within a layer and/or the number of fiber layers within the tape. Another subject of the present invention is a tape for producing a fiber composite material, as described above, the tape having a width transverse to the main orientation of the reinforcing fibers of at least 30 mm. The tape is formed from at least two hybrid rovings, which have a width transverse to the main direction of propagation of the reinforcing fibers of at least 15 mm, and whose reinforcing fibers lie next to each other without overlapping within the tape and lie next to each other without overlapping, transversely to the main direction of propagation of the reinforcing fibers. All of the above statements regarding the fiber composite material and the process for its production should apply equally to the tape. Likewise, all of the following explanations regarding the tape should apply both to the process for producing the fiber composite material and to the fiber composite material itself.

The tape has (at least) one fiber layer made of reinforcing fibers, which is formed from the fiber layers made of reinforcing fibers of at least two hybrid rovings, wherein the fiber layers made of reinforcing fibers of different hybrid rovings are provided next to each other, adjacent to one another, without overlap, within the tape (within the layer reinforcing fibers of the tape). Furthermore, the fiber layers made of thermoplastic fiber material of the tape are each formed from a plurality of fiber layers made of thermoplastic fibers of different hybrid rovings. Each layer of thermoplastic fiber material in the tape has at least two layers of thermoplastic fiber material of different hybrid rovings, which are provided within the thermoplastic fiber layer of the tape without overlap, next to one another, and lying against one another. The tape can also be formed from more than two hybrid rovings, whereby this tape is then constructed in the same way as the tape just described (only with more non-overlapping, side-by-side, adjoining fiber layers). The at least one tape can, for example, be formed from at least 3, at least 5 or at least 10 hybrid rovings, each layer of reinforcing fibers of the hybrid rovings having a width transverse to the main direction of propagation of the reinforcing fibers of at least 15 mm and the reinforcing fibers of different hybrid rovings. Rovings within the tape are adjacent to each other, transverse to the main direction of propagation of the reinforcing fibers, without overlapping (and thus form the layer of reinforcing fibers of the tape).

Within a tape, each hybrid roving can also have a first fiber layer made of thermoplastic fibers, which was formed from a different number of fibers and / or a different material type of fibers, like a second fiber layer made of thermoplastic fibers of the same hybrid roving.

The invention is described in more detail below with reference to figures, whereby the figures merely represent exemplary embodiments of the invention and are therefore not restrictive.

Figure 1 shows schematically a possible method of producing a hybrid roving

Figure 2 shows schematically an embodiment of a hybrid roving

Figure 3 shows schematically the structure of a tape.

Figure 4 shows schematically the arrangement of a plurality of tapes for producing the composite material Figure 5 shows schematically the structure with two tapes

Fiber composite material can be processed

A possibility for producing a hybrid roving is shown schematically in FIG. According to this example, a hybrid roving is made from three rolls of material as starting material. The outer material webs are spread thermoplastic fibers, in the middle a web of spread reinforcing fibers (e.g. glass fibers) is fed. The reinforcing fibers then lie between the sheets of thermoplastic fibers so that the thermoplastic fibers cover a top and a bottom of the reinforcing fibers. In one embodiment, before all fiber layers are brought together to form the hybrid roving, an adhesive and/or a binder can be applied to one of the fiber layers or to a plurality of the fiber layers. In another embodiment for producing the hybrid roving, all layers of thermoplastic fibers and all layers of reinforcing fibers are first combined to form a hybrid roving and then an adhesive and/or a binder is applied to the hybrid roving. The adhesive and/or the binder is preferably applied via a roller application, with one or more fiber webs or the hybrid roving being guided over a roller (roller) provided with the corresponding adhesive and/or binder. The fiber layers are layered on top of each other and then assembled and dried, preferably under pressure. This creates a fixation of the fiber layers to one another, so that the individual fiber layers cannot then be separated from each other again without appropriate effort. Preferably, the fixation of the different fiber layers within the hybrid roving is so strong that the hybrid roving can be easily wound up after fixation and unwound again later without the different fiber layers becoming separated. Furthermore, the fixation is so strong that too When producing the fiber composite material from hybrid roving (in the form of at least one tape), it retains its fiber layer structure.

An exemplary embodiment of a hybrid roving is shown schematically in FIG. In the example of Figure 2, the hybrid roving consists of a spread glass fiber roving, which is arranged between two spread rovings made of thermoplastic fibers. Preferably, the glass fiber roving is spread so that it has a thickness (measured in the direction from one fiber layer of thermoplastic fibers to the further fiber layer of thermoplastic fibers) that is greater than the individual thicknesses of the fiber layers of thermoplastic fibers. In the present case, the hybrid roving has three fiber layers, with two fiber layers consisting of the same material (thermoplastic fibers) and one fiber layer consisting of reinforcing fibers. The hybrid roving preferably has a width transverse to the main direction of propagation of the reinforcing fibers of more than 15 mm and at the same time also a thickness (measured in the direction from one fiber layer made of thermoplastic fibers to the further fiber layer made of thermoplastic fibers) which is between 0.2 and 0. is 4 mm. The hybrid roving therefore preferably has a width that is significantly larger than its thickness. The hybrid roving preferably has a width that is 20 to 25 times larger than its thickness.

A tape 1 is shown schematically in FIG. In the exemplary embodiment in FIG. 3, the tape 1 is formed from two hybrid rovings 2, 2', the hybrid rovings 2, 2' being next to each other without overlap and lying against one another within the tape 1. Preferably, within the tape 1, the first layer of thermoplastic fibers of the first and second hybrid rovings lies next to each other without overlap, while the layers of reinforcing fibers 3 of the first hybrid roving and the second hybrid roving lie next to each other within the tape without overlap on and the second layers of thermoplastic fiber material of the first and second hybrid rovings lie next to each other without overlapping, against each other. In Figure 3, the position of reinforcing fibers 3 of one of the hybrid rovings 2 has only been sketched.

4 shows again schematically the structure of the tape from at least two hybrid rovings 2.2 '. A first hybrid roving 2 has the same structure as a second hybrid roving 2 '. The hybrid rovings 2, 2' are placed together and form the tape 1. As can also be seen in the figure, the same fiber layers of the different hybrid rovings lie next to each other without overlapping, against each other within the tape 1. The different hybrid rovings 2, 2 'can, for example, have a binder or a pressure-sensitive adhesive, which enables the different fiber layers of each hybrid roving 2, 2' to be held together even without the fiber layers overlapping. Additionally or alternatively, the fiber layers of the hybrid rovings 2, 2' can also be connected by pressure and heat so that they form a tape 1 without overlap areas.

5 shows a structure with two tapes 1, which can be processed into fiber composite material. Each tape 1 has two hybrid rovings 2.2' or 2", 2'". The tapes 1 can, as in the example in FIG. 4, be arranged one above the other with an offset to one another, with these tapes lying within a horizontal layer of tapes 1 without any offset to one another. Preferably, the tapes 1 lie next to each other in a horizontal position without overlapping, against each other. The tapes 1 of different (horizontal) layers can be constructed the same or different from one another. The tapes 1 are preferably constructed in a horizontal layer in the same way as one another. A layer of reinforcing fibers 3 of a hybrid roving 2' was shown in outline.

Claims

Expectations:

1. Fiber composite material containing at least two hybrid rovings (2,2'), each of the at least two hybrid rovings (2,2') being constructed from at least one layer of reinforcing fibers (3) and at least two layers of thermoplastic fibers, wherein the at least one layer of reinforcing fibers (3) is arranged between the at least two layers of thermoplastic fibers in the hybrid roving (2, 2') and at least the reinforcing fibers within the fiber composite material are present in the fiber composite material without twisting, the layer of reinforcing fibers (3) and the layers of thermoplastic fibers of each hybrid roving (2,2') have a width transverse to the main direction of propagation of the reinforcing fibers, which is more than 15 mm, characterized in that the at least two hybrid rovings (2,2') transverse to Main direction of propagation of the reinforcing fibers are provided next to each other without overlap, adjacent to one another in at least one tape (1) within the fiber composite material, the at least one tape (1) having a width transverse to the main direction of propagation of the reinforcing fibers of at least 30 mm.

2. Fiber composite material according to claim 1, wherein the width of the at least one tape (1) transverse to the main direction of propagation of the reinforcing fibers is more than 50 mm, more than 100 mm, more than 250 mm, is more than 500 mm or more than 600 mm. Fiber composite material according to at least one of the preceding claims, wherein within the fiber layer of reinforcing fibers (3) in the hybrid roving and / or in the tape (1), the reinforcing fibers are provided next to one another and adjacent to one another without overlap. Fiber composite material according to at least one of the preceding claims, wherein in the case of a plurality of fiber layers made of reinforcing fibers (3) within a hybrid roving (2, 2 '), the different fiber layers made of reinforcing fibers (3) are offset or with at least partial areas perpendicular to the main direction of propagation of the reinforcing fibers Staggered, one above the other in the hybrid roving (2.2 '). Fiber composite material according to at least one of the preceding claims, wherein the fiber composite material has at least two tapes (1) which are arranged within the fiber composite material perpendicular to the main direction of propagation of the reinforcing fibers without offset or with an offset one above the other in the fiber composite material. Fiber composite material according to at least one of the preceding claims, wherein in each hybrid roving (2,2 ') and / or in at least one tape (1) within the fiber layer of reinforcing fibers (3) the weight per unit area is constant and / or within the layers thermoplastic fibers the basis weight is constant. Fiber composite material according to at least one of the preceding claims, wherein the at least two hybrid rovings have a temporary binder 8. Fiber composite material according to at least one of the preceding claims, wherein the fiber composite material has more than 10 hybrid rovings (2,2 '), but preferably fewer than 100 hybrid rovings (2,2').

9. Fiber composite material according to at least one of the preceding claims, wherein the fiber composite material has a homogeneous fiber distribution in the thickness and / or width direction.

10. Fiber composite material according to at least one of the preceding claims, wherein the fiber composite material is a pultrudate.

11. Fiber composite material according to claim 10, wherein the pultrudate has a rod shape and has a diameter of at least 2 mm.

12. Fiber composite material according to at least one of the preceding claims, wherein the layers of reinforcing fibers (3) of different hybrid rovings (2, 2 ') within the at least one tape (1) are adjacent to one another, adjoining one another, without adhesion and without overlap, transversely to the main direction of propagation of the reinforcing fibers.

13. A method for producing the fiber composite material according to claim 1, wherein at least two, preferably more than 10, hybrid rovings (2,2 ') are unwound and assembled into a fiber composite material, each hybrid roving (2,2') having a width of at least 15 mm transverse to the main direction of propagation of the reinforcing fibers, the hybrid rovings (2,2') lying next to each other transversely to the main direction of propagation of the reinforcing fibers without overlapping, forming at least one tape (1) which has a width transverse to the main direction of propagation of the reinforcing fibers of at least 30 mm and at least the reinforcing fibers are twist-free Fiber composite material can be joined together. Method for producing the fiber composite material according to claim 13, wherein not more than 400 hybrid rovings (2,2 ') are used for production, the fiber composite material having a width transverse to the main direction of propagation of the reinforcing fibers of more than 30 mm. Tape (1) for producing a fiber composite material according to claim 1, wherein the tape (1) is formed from at least two hybrid rovings (2,2 '), which have a width transverse to the main direction of propagation of the reinforcing fibers of at least 15 mm and their reinforcing fibers within of the tape (1) are adjacent to each other without overlapping, transverse to the main direction of propagation of the reinforcing fibers. Tape (1) according to claim 15, wherein the tape (1) is formed from at least 3, at least 5 or at least 10 hybrid rovings (2,2 '), each layer consisting of reinforcing fibers (3) of the hybrid rovings ( 2,2') has a width transverse to the main direction of propagation of the reinforcing fibers of at least 15 mm and the reinforcing fibers of different hybrid rovings (2,2') within the tape (1) lie next to one another, without adhesion and without overlap, adjacent to one another, transversely to the main direction of propagation of the reinforcing fibers.