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WO2010139077A1 - Procédé de production d'un matériau composite - Google Patents

Procédé de production d'un matériau composite Download PDF

Info

Publication number
WO2010139077A1
WO2010139077A1 PCT/CH2009/000349 CH2009000349W WO2010139077A1 WO 2010139077 A1 WO2010139077 A1 WO 2010139077A1 CH 2009000349 W CH2009000349 W CH 2009000349W WO 2010139077 A1 WO2010139077 A1 WO 2010139077A1
Authority
WO
WIPO (PCT)
Prior art keywords
core layer
reinforcing
fiber bundles
fibers
thermoplastic
Prior art date
Application number
PCT/CH2009/000349
Other languages
German (de)
English (en)
Inventor
Seyed Hassan Hosseini
Jerôme LEFEVRE
Karl-Ludwig Brentrup
Original Assignee
Quadrant Plastic Composites Ag
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 Quadrant Plastic Composites Ag filed Critical Quadrant Plastic Composites Ag
Publication of WO2010139077A1 publication Critical patent/WO2010139077A1/fr

Links

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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/82—Forcing wires, nets or the like partially or completely into the surface of an article, e.g. by cutting and pressing
    • 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
    • B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
    • B29C70/887—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced locally reinforced, e.g. by fillers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials

Definitions

  • the invention relates to a method for producing a composite material from a core layer containing air pores comprising random fibers reinforced thermoplastic and reinforcing strips of continuous, unidirectional reinforcing fibers, which are embossed on one or both sides in the surface of the core layer, and a composite material according to This method can be produced, and an existing acoustic panel.
  • thermoplastic materials containing air pores are known; they are widely used for automotive parts and construction. To improve their strength and the surface quality, they are covered with various cover layers.
  • cover layers in which one or more cover layers in the form of continuous or long thermoplastic fibers or prepregs containing parallel reinforcing fibers are hot-pressed onto a substrate layer having a density of less than 1.2 g / cm 3 .
  • a disadvantage of such laminates is that the porous surface of the substrate layer is completely or at least largely covered by the cover layers, so that the sound absorption capacity is drastically reduced.
  • WO 2008/101360 a process for the production of lightweight molded parts is described, in which in a two-part mold a heated blank of Kunststoffporen Vietnamesem, fiber-reinforced polypropylene and at its edge over Hinged GMT strips made of air-pore-free polypropylene are inserted, pressed and deformed.
  • the edge strips consist of a polypropylene matrix with short, undirected fibers.
  • the purpose of the GMT edge strips is to enable the thermally flowable GMT to penetrate into the edge regions of the mold during pressing for the production of the molded parts; from an improvement in particular the sound absorption capacity of the moldings by the short fibers contained in the edge strips is not mentioned, and this is not possible.
  • the core layer consists of a preferably 30 to 80 wt .-% random fibers reinforced matrix of a thermoplastic material containing preferably 20 to 80, in particular 30 to 70 vol .-% air voids.
  • This can be prepared, for example, by a process described in WO 2006/105682 by mixing glass fibers and polypropylene fibers, needling the mixed nonwoven fabric, heating to temperatures above the softening temperature of the polypropylene and pressing, for example in a double belt press at relatively low pressures.
  • polypropylene fibers or powder are mixed with glass fibers in aqueous suspension, the water is squeezed and the resulting plate is dried and hot pressed.
  • This core layer is preferably more than 3 mm, in particular 5 to 10 mm thick, and has a density of less than 1.0 g / cm 3 , preferably from 0.3 to 0.6 g / cm 3 .
  • Air-entrained composite panels are known and commercially available as sheets or panels of up to 300 cm in width, for example SymaLite from Quadrant Plastic Composites AG, SEEBERLITE from Röchling Automotive AG, ACOUSTIMAX from Owens Corning Corp., SUPERLITE from Hanwha and KARAMTEC the Karam Tech Corp.
  • reinforcing strips are embossed.
  • the core layer is heated to temperatures above the softening temperature of the thermoplastic material, and the surface is turned on or off applied on both sides of a plurality of individual reinforcing fiber bundles at a distance from each other and pressed into the surface.
  • the reinforcing fiber bundles are co-pressed on one or both sides by hot-pressing a needled composite fiber fleece from fibers of the thermoplastic polymer and reinforcing fibers onto a double-belt press. It is also possible to make the composite materials by pressing core layer webs with the reinforcing fiber bundles in a calender.
  • hybrid rovings are preferably used which consist of homogeneously mixed reinforcing fiber filaments and thermoplastic fiber filaments.
  • Preferred reinforcing fibers are glass fibers.
  • the thermoplastic is preferably identical, but at least compatible with the thermoplastic material of the core layer. Accordingly, the preferred thermoplastic is polypropylene, with the weight ratio of glass fibers to polypropylene fibers being between 53:47 and 82:18.
  • Such hybrid yarns are commercially available, eg TWINTEX from the company OCV.
  • pultruded thermoplastic fiber / glass fiber rovings can also be used.
  • the reinforcing fiber bundles can also consist of so-called Bico fibers with a core of reinforcing fibers and a sheath made of a thermoplastic, wherein the reinforcing fibers do not melt or only at a temperature higher by more than 40 0 C than the thermoplastic sheath.
  • the thermoplastic is preferably identical, but at least compatible with the thermoplastic material of the core layer.
  • thermoplastic component of the fibers melts during hot pressing and combines with the thermoplastic material of the core layer. In this way the penetration of the reinforcing fibers into the core layer is facilitated.
  • reinforcing fiber rovings or yarns which preferably have no rotation
  • thermoplastic component wherein for penetration a slightly higher pressure must be applied.
  • the fiber bundles have a titre of 50 to 3,000 tex and a practically round cross-section, the diameter preferably being between 0.25 and 5 mm, in particular between 1 and 4 mm.
  • the bundles are widened by applying a tensile stress of about 0.1 N to strips having a width of preferably 0.5 to 25 mm.
  • the fiber bundles are pressed into the surface of the core layer at a pressure of preferably 0.5 to 5 bar and a temperature which is at least 2O 0 C above the melting temperature of the thermoplastic material, is pressed so strong that the reinforcing fibers completely in the core layer penetrate so that it then has a flat surface.
  • a tension is exerted on the fiber bundles when the fiber bundles are applied to the core layer. In the preferred continuous process, this happens partly automatically when the fiber bundles are fed into the double belt press.
  • the tension of each fiber bundle can be individually controlled to achieve a greater spread. Due to the stress, the reinforcing fibers are strictly linearly aligned, which leads to an even better strength and rigidity of the composite materials in the fiber direction compared to the method according to WO 2005/070664.
  • the number of fiber bundles applied to the core layer depends on the width of the core layer. For narrow, from 30 cm wide core layers, for example, 4 to 10 fiber bundles are sufficient, with up to 300 cm wide core layers up to 100, preferably 10 to 50 fiber bundles can be applied. Per cm, preferably 0.4 to 4, in particular 0.5 to 2 fiber bundles are pressed. There is also the possibility of strengthening only in certain areas. applied to reinforce a component locally. In such cases, 4 fiber bundles per core layer are sufficient.
  • the fiber bundles may be passed over the recesses between the teeth of a comb and then applied to the surface of the core layer.
  • the distances of the teeth are displaceable, so that depending on the width of the core layer and the distances between the fiber bundles and thus the distances of the reinforcing strips are displaced from each other in the range of 3 mm to 5 mm. Greater distances can be achieved by skipping positions.
  • the fiber bundles are arranged parallel to one another and applied to the surface of the core layer.
  • the fiber bundles can be applied over the entire width of the web-shaped core layer in a zigzag form, being deposited from a cross-traversing depositing device on the forward-transported, heated web and pressed into the surface of the web in a double-belt press or calender.
  • the angle to the transport direction is about 45 °, optimum torsional rigidity of the composite panel is obtained.
  • the fiber bundles zigzag as narrow, z. B. 300 mm wide bands applied to the core layer web.
  • the fiber bundles can also be applied in the form of coarse-meshed mesh fabrics, which are formed, for example, from polypropylene fiberglass hybrid bundles, wherein the distances of the individual fiber bundles from each other in the grid can be eg 1 to 10 cm.
  • the reinforcing fibers glass fibers are preferred, besides carbon fibers, natural fibers, mineral fibers such as basalt fibers, liquid crystalline plastic fibers, thermoplastic reinforcing fibers having a preferably higher melting point of 40 0 C than the istmoplast used for the core layer, for example diveverstreckte fibers of polyethylene terephthalate , are used.
  • Polypropylene is preferred as well as polyethylene, polyamides and thermoplastic polyesters.
  • Another object of the invention is a composite material comprising
  • This composite material is preferably produced by the process according to the invention.
  • the composite has on its surface a sufficient number of open air pores, so that a good sound absorption is ensured.
  • a maximum of 50%, preferably a maximum of 30% and in particular less than 15% of the surface is formed by the pressed-in reinforcing strips.
  • a composite panel with many narrow strips, preferably more than 10 strips at a distance of at least 1 mm, preferably at least 3 mm, from each other, a better sound absorption has as a plate with only a wide, closed strip, or a plate which - as indicated in WO 2005/070664 - only partially covered with a cover layer, wherein the many narrow strips on the one hand and a strip or the cover layer on the other each occupy the same area.
  • the reinforcing strips can be attached to the core layer specifically where a gain is needed later in the component, or where they do not interfere with the subsequent deformation.
  • FIG. 1 shows in plan view a section of a core layer layer K with two mutually parallel hybrid rovings R consisting of reinforcing fibers VF and thermoplastic fibers TF.
  • FIG. 2 shows the arrangement of FIG. 1 corresponding to section A-A.
  • FIG. 3 shows a plan view of the above arrangement after the two rovings have been pressed in, wherein their reinforcing fibers are fused to the thermoplastic material of the core layer layer and thus only the uppermost reinforcing fibers VF are visible.
  • Each group of reinforcing fibers VF forms a reinforcing strip V.
  • Figure 4 shows the arrangement of Figure 3 corresponding to the section B-B. From Figures 3 and 4 it can be seen that the reinforcing strips V are completely pressed into the core layer K and the surface of the core layer is flat.
  • FIG. 5 shows a plan view of a section of a core layer layer K with a reinforcing strip V of individual reinforcing fibers VF pressed in in a zigzag fashion, the reinforcing strip extending over the entire width of the web-shaped core layer layer.
  • FIG. 6 shows in plan view a section of a core layer layer K with two narrow reinforcing strips V 1 pressed into it, each of which runs in a zigzag shape.
  • the composite materials according to the invention can be used for the production of components in the automotive industry, for example for headliners, as subfloors and as car load floors, furthermore in furniture construction and in construction, e.g. for sound absorbing ceiling panels.
  • the good sound absorption capacity is particularly important for automotive rooflights and furniture.
  • TWINTEX fiber bundles prestressed with a force of 0.1 N, and thereby widened to a width of approximately 7 mm each, were made of 60% by weight of glass fibers and 40% by weight of polypropylene fibers with a linear density of 1'860 Tex in a distance of 2 cm from each other in the central region of the web fed into the calender and applied to the surface of the web.
  • the expanded fiber bundles were embossed into the surface of the core layer web. Thereafter, the obtained composite plate was cooled.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention concerne un procédé de production d'un matériau composite comprenant A. une couche centrale (K) constituée d'une matière plastique thermoplastique renforcée par des fibres enchevêtrées et contenant au moins 20 % en volume de pores et B. des bandes de renforcement (V) constituées de fibres de renforcement continues, parallèles, unidirectionnelles qui sont enfoncées d'un côté ou des deux côtés dans la surface de la couche centrale, la couche centrale étant chauffée à des températures supérieures à la plage de ramollissement de la matière plastique thermoplastique. Ensuite une pluralité de faisceaux de fibres qui sont appliqués à distance les uns des autres sur la surface de la couche centrale est pressée dans celle-ci.
PCT/CH2009/000349 2009-06-04 2009-11-05 Procédé de production d'un matériau composite WO2010139077A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CH00855/09A CH701218A1 (de) 2009-06-04 2009-06-04 Verfahren zur Herstellung eines Verbundwerkstoffs.
CH855/09 2009-06-04

Publications (1)

Publication Number Publication Date
WO2010139077A1 true WO2010139077A1 (fr) 2010-12-09

Family

ID=41611214

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CH2009/000349 WO2010139077A1 (fr) 2009-06-04 2009-11-05 Procédé de production d'un matériau composite

Country Status (2)

Country Link
CH (1) CH701218A1 (fr)
WO (1) WO2010139077A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102014102079A1 (de) 2013-02-20 2014-08-21 Thüringisches Institut für Textil- und Kunststoff-Forschung e.V. Faserbasierte Trägerstruktur für Flüssigkeiten und Feststoffpartikel
US9205604B2 (en) 2012-06-19 2015-12-08 Airbus Group Limited Thermoplastic polymer powder
EP3078475A1 (fr) * 2015-04-07 2016-10-12 Ems-Patent Ag Corps de moulage renforcé par un élément de renfort, son procédé de fabrication et d'utilisation
EP3027100B1 (fr) 2013-07-29 2018-04-04 Schock GmbH Pièce moulée en forme d'évier (1), comme par exemple un évier de cuisine, un lavabo ou analogue et procédé de fabrication d'une telle pièce moulée en forme d'évier
EP4053350A1 (fr) 2021-03-04 2022-09-07 Hauraton GmbH & Co. KG Structure porteuse de demi-produit

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102013101726A1 (de) * 2013-02-21 2014-08-21 Sorcole GmbH Flächiges Leichtbaumaterial aus Verstärkungsfasern und thermoplastischem Kunststoff

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2162040A1 (fr) * 1971-11-29 1973-07-13 Saint Gobain
DE3822933A1 (de) * 1988-07-07 1990-01-11 Gefinex Jakon Gmbh Verfahren zur armierung von kunststoffschaum
WO2006105682A1 (fr) * 2005-04-05 2006-10-12 Quadrant Plastic Composites Ag Procede pour produire un demi-produit thermoplastiquement deformable renforce de fibres

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4214636A1 (de) * 1992-04-26 1993-10-28 Inst Polymerforschung Dresden Formbares, multiaxiales Verstärkungsgebilde
US20050153120A1 (en) * 2004-01-14 2005-07-14 General Electric Company Multilayer product made out of a substrate and on either side at least one cover layer; process for the manufacture of a multilayer product and painted multilayer product and process for painting a multilayer product
US8043542B2 (en) * 2007-02-19 2011-10-25 Quadrant Plastic Composites, AG Method for the production of fiber-reinforced polypropylene molded parts containing pores

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2162040A1 (fr) * 1971-11-29 1973-07-13 Saint Gobain
DE3822933A1 (de) * 1988-07-07 1990-01-11 Gefinex Jakon Gmbh Verfahren zur armierung von kunststoffschaum
WO2006105682A1 (fr) * 2005-04-05 2006-10-12 Quadrant Plastic Composites Ag Procede pour produire un demi-produit thermoplastiquement deformable renforce de fibres

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9205604B2 (en) 2012-06-19 2015-12-08 Airbus Group Limited Thermoplastic polymer powder
DE102014102079A1 (de) 2013-02-20 2014-08-21 Thüringisches Institut für Textil- und Kunststoff-Forschung e.V. Faserbasierte Trägerstruktur für Flüssigkeiten und Feststoffpartikel
WO2014128149A1 (fr) 2013-02-20 2014-08-28 Thüringisches Institut für Textil- und Kunststoff-Forschung e.V. Structure de support à base de fibres pour liquides et particules solides
EP3027100B1 (fr) 2013-07-29 2018-04-04 Schock GmbH Pièce moulée en forme d'évier (1), comme par exemple un évier de cuisine, un lavabo ou analogue et procédé de fabrication d'une telle pièce moulée en forme d'évier
EP3078475A1 (fr) * 2015-04-07 2016-10-12 Ems-Patent Ag Corps de moulage renforcé par un élément de renfort, son procédé de fabrication et d'utilisation
US10843389B2 (en) 2015-04-07 2020-11-24 Ems-Patent Ag Moulded article reinforced with a reinforcing element, method for production thereof and use thereof
EP4053350A1 (fr) 2021-03-04 2022-09-07 Hauraton GmbH & Co. KG Structure porteuse de demi-produit

Also Published As

Publication number Publication date
CH701218A1 (de) 2010-12-15

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