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CN110603136A - 制造热塑性聚合物复合材料部件的方法，和通过所述方法获得的物体 - Google Patents

制造热塑性聚合物复合材料部件的方法，和通过所述方法获得的物体 Download PDF

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Publication number
CN110603136A
CN110603136A CN201880031414.7A CN201880031414A CN110603136A CN 110603136 A CN110603136 A CN 110603136A CN 201880031414 A CN201880031414 A CN 201880031414A CN 110603136 A CN110603136 A CN 110603136A
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CN
China
Prior art keywords
meth
acrylic
thermoplastic polymer
weight
composite material
Prior art date
Legal status (The legal status 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 status listed.)
Pending
Application number
CN201880031414.7A
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English (en)
Inventor
V.博茨扎克
G.克莱达
P.格拉尔
M.格洛坦
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Arkema France SA
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Arkema France SA
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Filing date
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Application filed by Arkema France SA filed Critical Arkema France SA
Publication of CN110603136A publication Critical patent/CN110603136A/zh
Pending legal-status Critical Current

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    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/116—Single bevelled joints, i.e. one of the parts to be joined being bevelled in the joint area
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/116—Single bevelled joints, i.e. one of the parts to be joined being bevelled in the joint area
    • B29C66/1162—Single bevel to bevel joints, e.g. mitre joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • B29C66/52—Joining tubular articles, bars or profiled elements
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    • B29C66/5243—Joining profiled elements for forming corner connections, e.g. for making window frames or V-shaped pieces
    • B29C66/52431—Joining profiled elements for forming corner connections, e.g. for making window frames or V-shaped pieces with a right angle, e.g. for making L-shaped pieces
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B29C65/1412—Infrared [IR] radiation
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/22—Heated wire resistive ribbon, resistive band or resistive strip
    • B29C65/221—Heated wire resistive ribbon, resistive band or resistive strip characterised by the type of heated wire, resistive ribbon, band or strip
    • B29C65/222—Heated wire resistive ribbon, resistive band or resistive strip characterised by the type of heated wire, resistive ribbon, band or strip comprising at least a single heated wire
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3404—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint
    • B29C65/342—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint comprising at least a single wire, e.g. in the form of a winding
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3404—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint
    • B29C65/342—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint comprising at least a single wire, e.g. in the form of a winding
    • B29C65/3432—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint comprising at least a single wire, e.g. in the form of a winding comprising several wires, e.g. in the form of several independent windings
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3472—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint
    • B29C65/3476—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint being metallic
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3472—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint
    • B29C65/3484—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint being non-metallic
    • B29C65/3492—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint being non-metallic being carbon
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73117—Tg, i.e. glass transition temperature
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7377—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
    • B29C66/73771—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being amorphous
    • B29C66/73772—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being amorphous the to-be-joined areas of both parts to be joined being amorphous
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7377—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
    • B29C66/73773—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being semi-crystalline
    • B29C66/73774—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being semi-crystalline the to-be-joined areas of both parts to be joined being semi-crystalline
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7377—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
    • B29C66/73775—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being crystalline
    • B29C66/73776—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being crystalline the to-be-joined areas of both parts to be joined being crystalline
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
    • B29C66/73941—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset characterised by the materials of both parts being thermosets
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91211—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods
    • B29C66/91216—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods enabling contactless temperature measurements, e.g. using a pyrometer
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91221—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature of the parts to be joined
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及由至少两个由热塑性聚合物复合材料制成的部件（10）来制造由热塑性聚合物复合材料制成的物体（1）的方法（100），所述热塑性聚合物复合材料包含纤维增强材料和热塑性聚合物基质，所述方法包括以下步骤：在组装界面区域（11）处相邻或重叠布置（120）两个由热塑性聚合物复合材料制成的部件（10），在所述组装界面区域（11）处加热（130）以熔融该热塑性聚合物基质，从而形成包含焊接界面（12）的由热塑性聚合物复合材料制成的物体（1）。

Description

制造热塑性聚合物复合材料部件的方法，和通过所述方法获 得的物体
本发明属于热塑性聚合物复合材料制成的物体的领域。更特别地，本发明涉及制造由包含热塑性聚合物基质的聚合物复合材料制成的部件的方法。本发明还涉及热塑性聚合物复合材料制成的物体，特别是来自于此类方法。
[现有技术]
基于聚合物复合材料（包含固定在刚性聚合物基质中的纤维增强材料）的物体越来越多地用于所有领域，尤其是建筑、汽车、航空和航天领域。这是因为这些纤维增强的聚合物复合材料具有高强度/重量比和合意的机械性质，使得它们越来越广泛地用于制造物体如蒙皮、加强筋、横梁、白车身、成型件、短舱、门、尾翼、肋片、扰流板或襟翼。
用于生产这些物体的聚合物通常是热固性聚合物，生产这些物体的技术通常包括通过低压注塑、浸渍、灌注成型、真空辅助树脂灌注（VARI）、拉挤成型、真空灌注成型、加压灌注成型、树脂传递成型及其变体、或预浸料坯的模塑的工艺制造多个要组装的部件。
各种技术用于组装由聚合物复合材料制成的这些部件。这些连接技术主要包括机械紧固和粘合粘结（粘合剂）。铆钉组装的实施相对昂贵（例如就劳动而言）和复杂，并且所用铆钉提高了总重量。粘合剂粘结（例如环氧或聚酯或聚氨酯粘合剂）也是昂贵和复杂的，因为它们需要对要粘合粘结在一起的表面进行特殊准备，并通常需要实施特定固化和/或设备。此外，除了并非最佳的连接方式外，这些热固性聚合物复合材料是不可回收的。
为了应对这些问题，已经提出了生产热塑性材料制成的部件（其通过焊接技术来组装）。在焊接时，要组装的部件的温度升高至高于聚合物基质的熔点或软化点，将该部件放置在组装位置，直到树脂冷却以获得组装区域的机械结合。
由此，已经开发了热塑性聚合物制成的物体。它们通常是可回收的，并可以通过焊接技术连接。然而。热塑性聚合物制成的这些物体是通过与为了热固性聚合物复合材料制成的物体而开发的机器不兼容的方法形成的。此外，此类系统需要使用高温（通常高于100℃）以便生成待组装的部件。这种约束条件特别限制了生产大尺寸部件。
因此，需要能够应对现有方法造成的问题的制造由热塑性聚合物复合材料制成的物体的方法，该方法易于实施，并且不需要高温即可制造构成热塑性聚合物复合材料制成的物体的部件。
[技术问题]
本发明因此旨在克服现有技术的缺点。特别地，本发明的目的是提供比现有技术更快地制造由热塑性聚合物复合材料制成的部件的方法，并且还能够快速和容易地组装、维修或调整。
本发明的另一目的是提供由热塑性聚合物复合材料制成的物体，该物体可以比热固性聚合物复合材料制成的传统物体更快速地制造，同时优选主要是可回收的，并且耐受该物体在其使用过程中可能遇到的机械和化学应力。
[发明概述]
为此，本发明涉及由至少两个由热塑性聚合物复合材料制成的部件来制造由热塑性聚合物复合材料制成的物体的方法，所述热塑性聚合物复合材料包含纤维增强材料和热塑性聚合物基质，所述方法包括以下步骤：
- 在组装界面区域处相邻或重叠布置两个由热塑性聚合物复合材料制成的部件，
- 在所述组装界面区域处加热以熔融该热塑性聚合物基质，从而形成包含焊接界面的由热塑性聚合物复合材料制成的物体。
实际上，特别是与常规使用的热固性聚合物相比，使用使用包含(甲基)丙烯酸类热塑性聚合物的热塑性聚合物复合材料能够减少循环时间。由此，与使用热固性聚合物的常规方法相比，该方法能够节约生产时间。
此外，不同于由通常用于这些领域的热固性聚合物复合材料制成的物体，获自本发明的制造方法的由热塑性聚合物复合材料制成的物体易于回收。最后，焊接界面的存在经由提高界面温度提供了在不需要特别安装的情况下制造组装件、进行部件位置调整或维修的可能性。
根据该方法的其它任选特征：
- 该至少两个由热塑性聚合物复合材料制成的部件是由(甲基)丙烯酸类热塑性聚合物复合材料制成的部件。此外，该方法优选包括制造至少两个由(甲基)丙烯酸类热塑性聚合物复合材料制成的部件的在先步骤，该(甲基)丙烯酸类热塑性聚合物复合材料包含纤维增强材料和(甲基)丙烯酸类热塑性聚合物基质。实际上，在使用(甲基)丙烯酸类热塑性聚合物复合材料的背景下，本发明的制造方法可以使用采用当前最常用的工业设备（例如低压注塑、灌注成型）制造的热塑性聚合物复合材料部件来实施，因此，不同于诸如聚酰胺的热塑性聚合物复合材料制成的部件，其不需要修改目前用于本发明的各个应用领域的工业设备。由此，在这一实施方案中，不同于使用常规热塑性聚合物（例如聚酰胺）的方法，本发明的制造方法不包括在所有部件上升温至高温（例如>200℃），并由此能够容易地组装具有大尺寸的部件。
- 该纤维增强材料包含单独或混合物形式的选自碳纤维或玻璃纤维或玄武岩纤维或基于聚合物的纤维或植物纤维的纤维。
- 该纤维增强材料基于纵横比为至少1000的纤维。此类纵横比使得能够获得具有改善的机械性质的热塑性聚合物复合材料制成的物体。
- 制造至少两个由热塑性聚合物复合材料制成的部件的步骤包括以下子步骤：
- 用液体(甲基)丙烯酸类组合物浸渍纤维增强材料，
- 聚合该液体(甲基)丙烯酸类组合物。
- 该制造方法进一步包括在组装界面处施加压力的步骤。这使得能够用增强的焊接界面将至少两个由热塑性聚合物复合材料制成的部件焊接在一起。
- 该(甲基)丙烯酸类热塑性聚合物选自由通常称为“浆液”或热塑性聚合物树脂的液体(甲基)丙烯酸类组合物的(甲基)丙烯酸类热塑性聚合物。这种液体(甲基)丙烯酸类组合物用于浸渍该纤维增强材料，随后聚合。在聚合后，其构成该聚合物复合材料的基质。该聚合以良好的转化率快速进行（例如30秒至3小时）以提高生产率。包含(甲基)丙烯酸类单体和前体(甲基)丙烯酸类聚合物的液体组合物或浆液描述在WO 2013/056845和WO2014/013028中。例如，该前体(甲基)丙烯酸类热塑性聚合物选自聚(甲基丙烯酸甲酯)（PMMA）或甲基丙烯酸甲酯（MMA）的共聚物，或其混合物。优选地，该前体(甲基)丙烯酸类热塑性聚合物可以选自甲基丙烯酸甲酯（MMA）的均聚物或包含至少50%、优选至少70%、更优选至少80%、有利地为至少90%和更有利地为至少95重量%的甲基丙烯酸甲酯的共聚物。例如获自聚(甲基丙烯酸甲酯)（PMMA）或甲基丙烯酸甲酯（MMA）的共聚物，或其混合物的(甲基)丙烯酸类聚合物特别适于用于制造由聚合物复合材料制成的物体的现有工业方法，并赋予由聚合物复合材料制成的物体令人满意的机械和化学性质。
- 该(甲基)丙烯酸类热塑性聚合物具有50℃至160℃、优选70℃至140℃和甚至更优选90℃至120℃的玻璃化转变温度（Tg）。此外，该(甲基)丙烯酸类热塑性聚合物或一部分(甲基)丙烯酸类热塑性聚合物具有小于20克/10分钟的根据ISO 1133（230℃/3.8千克）的熔体流动指数（MFI）。该熔体流动指数优选小于18克/10分钟、更优选小于16克/10分钟、有利地小于13克/10分钟。这使得能够促进由聚合物复合材料制成的物体的生产，并能够容易地进行组装、调整或维修。
- 该(甲基)丙烯酸类热塑性聚合物基质还包含一种或多种添加剂或填料。所有任选的添加剂和填料在浸渍和/或聚合之前添加到该液体(甲基)丙烯酸类浆液中。作为添加剂，可以提及有机添加剂如冲击改性剂或嵌段共聚物、热稳定剂、UV稳定剂、润滑剂及其混合物。该冲击改性剂为具有弹性体芯和至少一个热塑性壳的微细粒子形式，该粒子的尺寸通常小于1 μm并有利地为50至300 nm。该冲击改性剂优选通过乳液聚合来制备。热塑性聚合物基质中冲击改性剂的比例为0至50重量%、优选0至25重量%、有利地为0至20重量%。作为填料，可以提及碳纳米管或矿物填料，包括矿物纳米填料（TiO2、二氧化硅）。
- 由热塑性聚合物复合材料制成的部件在小于150℃、优选小于120℃、甚至更优选小于100℃的温度下制造。实际上，在由聚合物复合材料制成的部件的制造过程中使用的液体(甲基)丙烯酸类组合物在远低于常规热塑性塑料的常规熔点的温度下为液体。由此，这使得能够生产非常大尺寸的由热塑性聚合物复合材料制成的部件，而无需实施将所述部件加热至高温的过程。
- 由热塑性聚合物复合材料制成的部件通过低压注塑、灌注成型或通过模塑用(甲基)丙烯酸类热塑性聚合物复合材料预浸渍的条带来制造。
- 所述两个由热塑性聚合物复合材料制成的部件中的至少一个在意在被焊接的表面上包含至少0.5 mm、优选1 mm、更优选至少2 mm厚的(甲基)丙烯酸类热塑性聚合物层。这特别使得能够避免在焊接界面处出现具有较低浓度树脂的区域，而这可能导致由热塑性聚合物复合材料制成的物体变脆。
- 在加热步骤过程中，组装界面处的温度为160至300℃、优选200至250℃。
- 该热塑性聚合物基质、优选(甲基)丙烯酸类热塑性聚合物基质通过选自以下的技术来熔融：超声波焊接、感应焊接、电阻丝焊接、搅拌摩擦焊接、激光焊接、通过红外或紫外辐射加热，优选通过电阻丝焊接。
- 所述两个由热塑性聚合物复合材料制成的部件中的至少一个包含至少一个位于组装界面处的电阻丝。
本发明进一步涉及由至少两个由热塑性聚合物复合材料制成的部件制造的由热塑性聚合物复合材料制成的物体，其特征在于所述热塑性聚合物复合材料包含纤维增强材料和热塑性聚合物基质、优选(甲基)丙烯酸类热塑性聚合物基质，并且在于所述至少两个由热塑性聚合物复合材料制成的部件通过焊接界面来连接。
根据该物体的其它任选特征：
- 由热塑性聚合物复合材料制成的物体不包含超过50%、优选不超过40%、更优选不超过30%、甚至更优选不超过20%、更有利地不超过15重量%和甚至更有利地不超过10重量%的热固性聚合物如环氧树脂。由此，本发明的由热塑性聚合物复合材料制成的物体在生产时间方面具有非常显著的收益，并具有提高的再循环能力。同样，由热塑性聚合物复合材料制成的物体不包含超过10重量%、优选不超过8重量%、有利地不超过7重量%、更有利地不超过6重量%和甚至更有利地不超过5重量%的粘合剂，优选热固性粘合剂。
- 所述由热塑性聚合物复合材料制成的物体选自：由多个板组成的包覆物、栏杆、窗型材、飞机机身、建筑的加固件、横梁（尤其用于车辆）、白车身部件(body in whitepart)、吊舱、尾翼、肋片、扰流板、襟翼、船用涡轮叶片、船体、船桥、船用舱壁和用于汽车的饰板（罩）。
本发明的其它优点和特征将在参照附图阅读作为说明性和非限制性实例给出的以下描述时变得显而易见，所述附图描绘了：
• 图1：本发明的制造方法的优选实施方案的流程图。具有虚线的步骤是任选的。
• 图2A至2E：由热塑性聚合物复合材料制成的部件的组装件的截面示意图。
• 图3A和3B：根据本发明的方法组装的窗型材的两个部分的纵向截面的以顶视图显示的两个简化图示。
• 图4A和4B：本发明的车辆横梁的示意性透视图。
• 图5：本发明的飞机机身部分的示意性透视图。
[发明详述]
在说明书的剩余部分中，“焊接界面”对应于部件、或部件的一部分之间的焊接接头。其是指熔融区域，也就是说热塑性聚合物在焊接操作过程中成为液态的区域。本发明的焊接可以在提供或不提供热塑性填充材料，尤其是(甲基)丙烯酸类热塑性填充材料的情况下进行。
对本发明而言，术语“电阻丝”是指包含电阻率在20℃下大于1×10-2 Ω mm²/m、例如在20℃下大于0.1 Ω mm²/m的材料的长丝。该电阻丝例如可以包含金属或金属合金或基于碳的任何其它有机导电元件，如基于炭黑、碳纳米管、石墨烯的导电聚合物膜或线材。优选地，该电阻丝具有高熔点，大于本发明的(甲基)丙烯酸类热塑性聚合物的软化点或倾点（例如玻璃化转变温度）。该电阻丝的熔点优选大于300℃、更优选大于500℃、例如大于750℃。在导电聚合物膜或线材的情况下，其必须具有至少等于该热塑性聚合物、优选(甲基)丙烯酸类热塑性聚合物的倾点。
对本发明而言，表述“聚合物复合材料”表示包含至少两种不混溶的组分的多组分材料，其中至少一种组分是聚合物，另一种组分可以例如是纤维增强材料。
对本发明而言，“纤维增强材料”或“纤维质基材”是指多个纤维、单向粗纱或连续长丝毡、织物、毛毡或无纺织物，其可以为条带、网幅、穗带、股线或部件形式。
“基质”是指充当粘合剂的材料，其能够将力传递至该纤维增强材料。“聚合物基质”包含聚合物，但还可以包含其它化合物或材料。由此，该“(甲基)丙烯酸类聚合物基质”是指丙烯酸和甲基丙烯酸类的任何类型的化合物、聚合物、低聚物、共聚物或嵌段共聚物。但是，如果(甲基)丙烯酸类聚合物基质包含至多10重量%、优选小于5重量%的其它非丙烯酸类单体的话，将不脱离本发明的范围，所述非丙烯酸类单体选自例如：丁二烯、异戊二烯、苯乙烯、取代苯乙烯如α-甲基苯乙烯或叔丁基苯乙烯、环硅氧烷、乙烯基萘和乙烯基吡啶。
“聚合物”是指共聚物或均聚物。“共聚物”是指几种不同的单体单元组合在一起的聚合物，“均聚物”是指相同的单体单元组合在一起的聚合物。“嵌段共聚物”是指包含每种单独的聚合物实体的一个或多个不间断序列的聚合物，该聚合物序列在化学上彼此不同，并通过共价键彼此键合。这些聚合物序列也被称为聚合物嵌段。
对本发明而言，术语“自由基引发剂”是指可以启动/引发一种或多种单体的聚合反应的化合物。
对本发明而言，术语“聚合”是指单体或单体的混合物转化为聚合物的过程。
对本发明而言，术语“单体”是指可以发生聚合的分子。
对本发明而言，“热塑性聚合物”是指在室温下通常为固体的聚合物，其是结晶、半结晶或无定形的，该聚合物在升温过程中，特别是在达到其玻璃化转变温度（Tg）后软化，并在更高温度下流动，并在达到其“熔点”（Tm）（当其为半结晶的时）可以表现出明显的熔融，在低于其熔点且低于其玻璃化转变温度的降温过程中再次变成固体。这也适用于通过(甲基)丙烯酸酯“浆液”的配方中以优选小于10%、优选小于5%和更优选小于2%的重量百分比存在多官能单体或低聚物而略微交联的热塑性聚合物，其在加热至高于软化点时可以热成形。
对本发明而言，“热固性聚合物”是指通过聚合不可逆地转化为不溶性聚合物网络的塑料材料。
“(甲基)丙烯酸类单体”是指任何类型的丙烯酸和甲基丙烯酸类单体。
“(甲基)丙烯酸类聚合物”是指基本上包含(甲基)丙烯酸类单体的聚合物，该单体占所述(甲基)丙烯酸类聚合物的至少50重量%或更多。
对本发明而言，术语“PMMA”表示甲基丙烯酸甲酯（MMA）的均聚物和共聚物，PMMA中MMA的重量比优选对MMA共聚物为至少70重量%。
在说明书的剩余部分中，相同的附图标记用于指示相同的元件。
根据第一方面，如图1中所示，本发明涉及由至少两个由热塑性聚合物复合材料制成的部件制造由热塑性聚合物复合材料制成的物体1的方法100，所述热塑性聚合物复合材料包含纤维增强材料和热塑性聚合物基质。优选地，该方法由至少两个由(甲基)丙烯酸类热塑性聚合物复合材料制成的部件开始进行，所述(甲基)丙烯酸类热塑性聚合物复合材料包含纤维增强材料和(甲基)丙烯酸类热塑性聚合物基质。
这种方法主要包括以下步骤：
- 在组装界面区域11处相邻或重叠布置120两个由热塑性聚合物复合材料制成的部件10，
- 在所述组装界面区域11处加热130以熔融该热塑性聚合物基质，以便形成包含焊接界面12的由热塑性聚合物复合材料制成的物体1。
构成与该纤维增强材料缔合的基质的一部分的(甲基)丙烯酸类热塑性聚合物可以选自丙烯酸类的聚合物和共聚物，如聚丙烯酸酯。它们更特别选自聚甲基丙烯酸甲酯（PMMA）或其衍生物或甲基丙烯酸甲酯（MMA）的共聚物，或其混合物。
优选地，构成该(甲基)丙烯酸类热塑性聚合物基质的(甲基)丙烯酸类热塑性聚合物具有50℃至160℃、优选70℃至140℃和甚至更优选90℃至120℃的玻璃化转变温度（Tg），这与其它热塑性聚合物如聚胺相比是有利的。实际上，聚胺通常具有非常高的熔点，即200℃至更高，这不像本发明的方法那样有利于现场组装。玻璃化转变温度或熔点可以通过本领域技术人员公知的方法来测量。优选地，这些温度通过差示扫描量热法根据用于Tg的标准ISO 11357-2/2013和用于Tm的标准ISO 11357-3/2011中规定的条件测得。此外，该(甲基)丙烯酸类热塑性聚合物或一部分(甲基)丙烯酸类热塑性聚合物具有小于20克/10分钟的根据ISO 1133（230℃/3.8 kg）的熔体流动指数（MFI）。优选地，该熔体流动指数小于18克/10分钟、更优选小于16克/10分钟、有利地为0.1克至13克/10分钟。
如下文将要详细描述的那样，该(甲基)丙烯酸类热塑性聚合物基质可以获自包含(甲基)丙烯酸类单体或(甲基)丙烯酸类单体的混合物、(甲基)丙烯酸类聚合物和至少一种自由基引发剂的液体(甲基)丙烯酸类组合物的聚合。
该(甲基)丙烯酸类热塑性聚合物基质由(甲基)丙烯酸类热塑性聚合物构成，但是可以进一步包含一种或多种添加剂和/或一种或多种填料。
该碳质填料特别可以是活性炭、天然无烟煤、合成无烟煤、炭黑、天然石墨、合成石墨、碳质纳米填料或其混合物。它们优选选自碳质纳米填料，特别是石墨烯和/或碳纳米管和/或碳纳米微纤丝或其混合物。这些填料能够导电和导热，并因此能够在加热时改善该聚合物基质的润滑。它们随后能够缩短循环时间或便于在安装现场的组装、调整或维修。
该矿物填料特别包括金属氢氧化物，其更特别为三水合氧化铝（Al(OH)3）或氢氧化镁（Mg(OH)）的形式，以及矿物纳米填料如碳酸钙、二氧化钛或二氧化硅。
作为添加剂，可以提及有机添加剂如冲击强度改性剂或嵌段共聚物、热稳定剂、UV稳定剂、润滑剂、粘度改性剂、pH调节剂（氢氧化钠）、粒度调节剂（硫酸钠）、杀生物剂及其混合物。这些添加剂特别能够改善该(甲基)丙烯酸类热塑性聚合物基质的流变、化学和粘附性质。
所有添加剂和填料相对于(甲基)丙烯酸类热塑性聚合物基质的总重量的重量百分比优选小于30%、优选小于10%。
纤维增强材料通常是指多个纤维、单向粗纱或连续长丝毡、织物、毛毡或无纺织物，其可以为条带、网幅、穗带、股线或部件形式。更特别地，纤维增强材料包含一种或多种纤维，通常为数种纤维的组装件，所述组装件能够具有不同的形式和尺寸；一维、二维或三维。一维形式对应于线性长纤维。该纤维可以是不连续的或连续的。该纤维可以以连续长丝形式随机地或彼此平行地排列。二维形式对应于非织造增强材料或纤维毡或织造粗纱或纤维束，其也可以是编织的。即使二维形式具有特定的厚并因此在原则上是三维的，其根据本发明也被视为二维的。三维形式例如对应于堆叠或折叠的非织造纤维增强材料或纤维毡或织造粗纱或纤维束，或其混合物；一种二维形式在三维中的组装件。
该纤维可以是不连续的或连续的。当该纤维是连续的时，其组装件形成织物。优选地，该纤维增强材料基于连续纤维。纤维由其纵横比来定义，纵横比是纤维长度与直径之间的比。本发明中使用的纤维是获自连续纤维的长纤维，或连续纤维。该纤维具有至少1000、优选至少1500、更优选至少2000、有利地至少3000和更有利地为至少5000、甚至更有利地为至少6000、甚至更有利地为至少7500和最有利地为至少10 000的纵横比。该连续纤维具有至少1000的纵横比。纤维的尺寸可以通过本领域技术人员公知的方法来测量。优选地，这些尺寸根据标准ISO 137通过显微镜法来测量。
构成该纤维增强材料的纤维的来源可以是天然或合成的。可以提及的天然材料包括植物纤维、木纤维、动物纤维或矿物纤维。植物纤维是例如剑麻、黄麻、大麻、亚麻、棉花、椰子和香蕉纤维。动物纤维是例如羊毛或毛皮。矿物纤维也可以选自玻璃纤维（特别是E、R或S2型）、玄武岩纤维、碳纤维、硼纤维或二氧化硅纤维。
可以提及的合成材料包括选自热固性聚合物纤维、热塑性聚合物或其混合物的聚合物纤维。该聚合物纤维可以由聚酰胺（脂族或芳族）、聚酯、聚乙烯醇、聚烯烃、聚氨酯、聚氯乙烯、聚乙烯、不饱和聚酯、环氧树脂和乙烯基酯组成。
优选地，本发明的纤维增强材料单独或以混合物形式包含植物纤维、木纤维、动物纤维、矿物纤维、合成聚合物纤维、玻璃纤维、玄武岩纤维和碳纤维。更优选地，本发明的纤维增强材料包含碳纤维或玻璃纤维。更优选地，本发明的纤维增强材料基本上由天然纤维（织物纤维或木纤维）、碳纤维或玻璃纤维组成。
该纤维增强材料的纤维具有例如0.005 µm至100 µm、优选1 µm至50 µm、更优选5µm至30 µm和有利地为10 µm至25 µm的直径。
优选地，本发明的纤维增强材料的纤维对该纤维增强材料的一维形式而言选自连续纤维，或对该纤维增强材料的二维或三维形式而言选自长纤维或连续纤维。
如图1中所示，制造110至少两个由(甲基)丙烯酸类热塑性聚合物复合材料制成的部件10的第一任选步骤可以包括以下子步骤：
- 用液体(甲基)丙烯酸类组合物浸渍111纤维增强材料，
- 聚合112浸渍所述纤维增强材料的液体(甲基)丙烯酸类组合物。
本发明的优点之一在于由热塑性聚合物复合材料制成的部件10可以在小于150℃、优选小于140℃、甚至更优选小于125℃、有利地小于120℃、更有利地小于110℃和甚至更有利地小于100℃的温度下制造。例如，用液体(甲基)丙烯酸类组合物浸渍该纤维增强材料的步骤在小于150℃、优选小于120℃、甚至更优选小于100℃或小于80℃的温度下进行。实际上，用于制造由热塑性聚合物复合材料制成的部件10的液体(甲基)丙烯酸类组合物在远低于常规热塑性塑料的常规熔点的温度下为液体。由此，这使得能够生产非常大尺寸的由热塑性聚合物复合材料制成的部件10，而无需实施将所述部件加热至高温的过程。由此，应当理解的是，可用于制造这些部件的方法不需要像使用常规热塑性塑料的情况那样的在高温下加热的步骤。
制造由热塑性聚合物复合材料制成的部件10的步骤110还可以包含沉积(甲基)丙烯酸类热塑性聚合物的层的子步骤113。这种沉积可以优选在意在形成未来的焊接型界面的组装界面区域处。或者，该沉积在整个由热塑性聚合物复合材料制成的部件10上进行。
关于制造由热塑性聚合物复合材料制成的部件10的步骤110，可以采用不同的方法来制造这些部件。可以提及真空辅助树脂灌注（VARI）、拉挤成型、真空灌注成型、加压灌注成型、高压釜成型、树脂传递成型（RTM）及其变体（如HP-RTM、C-RTM、I-RTM）、反应注塑成型（RIM）、增强反应注射成型（R-RIM）及其变体、冲压成型、压缩成型、液体压缩成型（LCM）或片材成型（SMC）或块状成型（BMC）。
制造由热塑性聚合物复合材料制成的部件10的第一优选制造方法是通过在模具中浸渍该纤维增强材料将液体(甲基)丙烯酸类组合物转移到该纤维增强材料上的方法。需要模具的方法列举在上文中，并包括词语成型。
制造由热塑性聚合物复合材料制成的部件10的第二优选制造方法是在拉挤成型工艺中使用该液体组合物的方法。引导该纤维经过包含本发明的组合物的树脂浴（原文batch疑为bath之误）。纤维增强材料形式的纤维例如为单向粗纱或连续长丝毡的形式。在树脂浴中浸渍后，将湿纤维拉过加热的模头，在那里发生聚合。
第三优选制造方法是真空辅助树脂灌注（VARI）。
制造由热塑性聚合物复合材料制成的部件10以及机械或结构部件或产品的方法可以进一步包括后成型步骤。后成型包括弯曲以及修改复合材料部件的形状。制造由热塑性聚合物复合材料制成的部件10的方法可以进一步包括轧制步骤。
通过本发明的方法获得的热塑性部件可以在本发明的液体组合物聚合后进行后成型。成型包括弯曲和修改复合材料部件的形状。
关于该液体(甲基)丙烯酸类组合物，其可以如WO 2013/056845和WO 2014/013028中所述包含(甲基)丙烯酸类单体、前体(甲基)丙烯酸类聚合物和自由基引发剂。
此外，在浸渍过程中，在制备聚合物复合材料时，必须调节和调整该液体(甲基)丙烯酸类组合物或浸渍浆液的粘度，以使其不会流动性太高或粘性太高，以便正确地浸渍该纤维增强材料的每根纤维。当由于浆液的流动性太高或粘性太高而部分润湿时，分别出现“裸露”区域（即未浸渍区域）和在该纤维上形成聚合物液滴的区域，这是气泡形成的原因。这些“裸露”区域和这些气泡导致在最终复合材料中出现缺陷，这些缺陷尤其是导致最终复合材料的机械强度降低的原因。此外，在不浸渍而使用的情况下，为了提高生产率，合意的是具有以良好的转化率快速聚合的液体组合物。
由此，所述液体(甲基)丙烯酸类组合物在25℃下的动态粘度优选为10 mPa*s至10000 mPa*s。该液体组合物或该(甲基)丙烯酸类浆液的动态黏度为10 mPa*s至10000 mPa*s、优选20 mPa*s至7000 mPa*s和有利地为20 mPa*s至5000 mPa*s。该液体(甲基)丙烯酸类组合物或液体(甲基)丙烯酸类浆液的粘度可以用流变仪或粘度计容易地测量。动态粘度在25℃下测量。如果该液体(甲基)丙烯酸类浆液表现出牛顿特性，即不发生剪切稀化，则该动态粘度与流变仪中的剪切或粘度计中心轴的速度无关。如果液体组合物表现出非牛顿行为，即发生剪切稀化，该动态粘度在25℃下以1 s-1的剪切速率测量。
该液体(甲基)丙烯酸类组合物包含至少一种(甲基)丙烯酸类单体或(甲基)丙烯酸类单体的混合物、前体(甲基)丙烯酸类聚合物。
该液体(甲基)丙烯酸类组合物或该液体(甲基)丙烯酸类浆液中(甲基)丙烯酸类单体或(甲基)丙烯酸类单体的混合物以液体(甲基)丙烯酸类组合物中至少40重量%、优选至少45重量%、更优选至少50重量%、有利地为至少60重量%和更有利地为至少65重量%的量存在。
该液体(甲基)丙烯酸类组合物或该液体(甲基)丙烯酸类浆液中的前体(甲基)丙烯酸类聚合物以液体(甲基)丙烯酸类组合物中至少10重量%、优选至少15重量%、有利地为至少18重量%和更有利地为至少20重量%的量存在。
该液体(甲基)丙烯酸类组合物或该液体(甲基)丙烯酸类浆液中的前体(甲基)丙烯酸类聚合物以液体(甲基)丙烯酸类组合物中至多60重量%、优选至多50重量%、有利地为至多40重量%和更有利地为至多35重量%的量存在。
该液体(甲基)丙烯酸类组合物或该浆液，该浆液化合物以下列重量百分比混入：
• 该液体组合物或该(甲基)丙烯酸类浆液中的(甲基)丙烯酸类单体以(甲基)丙烯酸类单体和(甲基)丙烯酸类聚合物所组成的组合物的40重量%至90重量%和优选45重量%至85重量%的比例存在，
• 该液体组合物或该(甲基)丙烯酸类浆液中的(甲基)丙烯酸类聚合物以(甲基)丙烯酸类单体和(甲基)丙烯酸类聚合物所组成的组合物的10重量%至60重量%和有利地为15重量%至55重量%的比例存在；优选地，该液体组合物中的(甲基)丙烯酸类聚合物以(甲基)丙烯酸类单体和(甲基)丙烯酸类聚合物所组成的组合物的18重量%至30重量%、更优选20重量%至25重量%的比例存在。
作为(甲基)丙烯酸类单体，该单体选自丙烯酸、甲基丙烯酸、烷基丙烯酸类单体、烷基甲基丙烯酸类单体、羟烷基丙烯酸类单体和羟烷基甲基丙烯酸类单体，及其混合物。
优选地，该(甲基)丙烯酸类单体选自丙烯酸、甲基丙烯酸、羟烷基丙烯酸类单体、羟烷基甲基丙烯酸类单体、烷基丙烯酸类单体、烷基甲基丙烯酸类单体及其混合物，该烷基基团含有1至22个直链、支链或环状的碳；该烷基优选含有1至12个直链、支链或环状的碳。
有利地，该(甲基)丙烯酸类单体选自甲基丙烯酸甲酯、甲基丙烯酸乙酯、丙烯酸甲酯、丙烯酸乙酯、甲基丙烯酸、丙烯酸、丙烯酸正丁酯、丙烯酸异丁酯、甲基丙烯酸正丁酯、甲基丙烯酸异丁酯、丙烯酸环己酯、甲基丙烯酸环己酯、丙烯酸异冰片酯、甲基丙烯酸异冰片酯、丙烯酸羟乙酯和甲基丙烯酸羟乙酯，及其混合物。
根据一个优选实施方案，该(甲基)丙烯酸类单体的至少50重量%和优选至少60重量%是甲基丙烯酸甲酯。
根据第一更优选的实施方案，该单体的至少50重量%、优选至少60重量%、更优选至少70重量%、有利地为至少80重量%和甚至更有利地为90重量%是甲基丙烯酸甲酯任选与至少一种其它单体的混合物。
关于该前体(甲基)丙烯酸类聚合物，可以提及聚甲基丙烯酸烷基酯或聚丙烯酸烷基酯。根据一个优选实施方案，该前体(甲基)丙烯酸类聚合物是聚(甲基丙烯酸甲酯)（PMMA）。
根据一个实施方案，该甲基丙烯酸甲酯（MMA）均聚物或共聚物包含至少70%、优选至少80%、有利地为至少90%和更有利地为至少95重量%的甲基丙烯酸甲酯。
根据另一实施方案，该PMMA是MMA的至少一种均聚物和至少一种共聚物的混合物、或具有不同平均分子量的MMA的至少两种均聚物或两种共聚物的混合物、或具有不同单体组成的MMA的至少两种共聚物的混合物。
甲基丙烯酸甲酯（MMA）的共聚物包含70重量%至99.7重量%的甲基丙烯酸甲酯和0.3重量%至30重量%的至少一种含有至少一个可以与甲基丙烯酸甲酯共聚的烯键式不饱和的单体。
这些单体是公知的，并且特别可以提及丙烯酸和甲基丙烯酸以及(甲基)丙烯酸烷基酯,其中该烷基含有1至12个碳原子。例如可以提及丙烯酸甲酯和(甲基)丙烯酸乙酯、丁酯或2-乙基己酯。优选地，该共聚单体是丙烯酸烷基酯，其中该烷基含有1至4个碳原子。
根据第一优选的实施方案，甲基丙烯酸甲酯（MMA）的共聚物包含80重量%至99.7重量%、有利地为90重量%至99.7重量%和更有利地为90重量%至99.5重量%的甲基丙烯酸甲酯，和0.3重量%至20重量%、有利地为0.3重量%至10重量%和更有利地为0.5重量%至10重量%的至少一种单体，该单体含有至少一个可以与该甲基丙烯酸甲酯共聚的烯键式不饱和。优选地，该共聚单体选自丙烯酸甲酯和丙烯酸乙酯及其混合物。
该前体(甲基)丙烯酸类聚合物的重均分子量应当较高，意味着大于50 000 g/mol、优选大于100 000 g/mol。该重均分子量可以通过尺寸排阻色谱法测得。
该前体(甲基)丙烯酸类聚合物完全溶于(甲基)丙烯酸类单体或溶于(甲基)丙烯酸类单体的混合物。这可以提高(甲基)丙烯酸类单体或(甲基)丙烯酸类单体的混合物的粘度。获得的液体组合物或溶液通常被称为“浆液”或“预聚物”。该液体(甲基)丙烯酸类浆液的动态粘度值为10 mPa.s至10 000 mPa.s。该浆液的粘度可以用流变仪或粘度计容易地测量。动态粘度在25℃下测量。有利地，该液体(甲基)丙烯酸类浆液不含有意加入的附加溶剂。
关于自由基引发剂，可以提及优选水溶性的自由基聚合引发剂或脂溶性的或部分脂溶性的自由基聚合引发剂。
水溶性自由基聚合引发剂特别是过硫酸氢钠、钾或铵，单独使用或在还原剂如焦亚硫酸钠或连二亚硫酸氢钠、硫代硫酸钠、甲醛次硫酸氢钠、2-羟基-2-亚磺基乙酸、亚硫酸钠和2-羟基-2-磺基乙酸的二钠盐的混合物、或羟基亚磺基乙酸的二钠盐和羟基磺基乙酸的二钠盐的混合物的存在下使用。
脂溶性或部分脂溶性的自由基聚合引发剂特别是过氧化物或氢过氧化物和偶氮二异丁腈的衍生物。过氧化物或氢过氧化物与上述还原剂组合使用，以降低其活化温度。
引发剂相对于单体混合物的总重量的重量百分比优选为0.05重量%至3重量%、优选0.1重量%至2重量%。
在图2中显示了在组装界面区域11处相邻或重叠布置120两个由热塑性聚合物复合材料制成的部件10的步骤。由此，图2A显示了相邻定位并通过组装界面区域11隔开的两个由热塑性聚合物复合材料制成的部件10。由热塑性聚合物复合材料制成的部件的末端相邻定位以形成组装界面区域11。如图2B中所示，该末端可以由所述由热塑性聚合物复合材料制成的部件10的横截面形成，由此形成横向焊接界面12。
如图2C至2E中所示，由热塑性聚合物复合材料制成的部件10还可以定位以便重叠，并因此形成对应于这些图中所示的未来的焊接界面12的覆盖区域。
此外，所述由热塑性聚合物复合材料制成的部件10可以包含(甲基)丙烯酸类热塑性聚合物的层13。如前所述，层13可以优选定位在意在形成未来的焊接界面12的组装界面区域处（图2D）。或者，如图2E中所示，在整个由热塑性聚合物复合材料制成的部件10上沉积层13。所述沉积特别能够在意在被焊接的表面上获得至少0.5 mm厚的(甲基)丙烯酸类热塑性聚合物的层13。
特别地，该焊接或焊接性界面12具有大于或等于1 mm、优选大于或等于2 mm的厚度。该焊接界面12的厚度可以通过常规方法，例如由所述焊接界面12的垂直截面测得。
图2A至2E仅描绘了焊接界面12的截面图，但是后者优选在由热塑性聚合物复合材料制成的部件10的较大长度上延伸。由此，该焊接界面12可以具有大于1米、优选大于5米和甚至更优选大于10米的长度。此外，本发明的方法特别适于大型的由热塑性聚合物复合材料制成的部件10。由此，优选地，所述两个由热塑性聚合物复合材料制成的部件10中的至少一个包含大于1米、优选大于2米的尺寸。
该加热步骤130能够在所述组装界面区域11处熔融该(甲基)丙烯酸类热塑性聚合物基质，从而形成包含焊接界面12的由热塑性聚合物复合材料制成的物体1。该(甲基)丙烯酸类热塑性聚合物基质可以通过选自以下的技术来熔融：超声波焊接、感应焊接、电阻丝焊接、搅拌摩擦焊接、激光焊接、通过红外或紫外辐射加热。优选地，该(甲基)丙烯酸类热塑性聚合物基质通过电阻丝焊接来熔融。
本发明的焊接可以在提供或不提供(甲基)丙烯酸类热塑性填充材料的情况下进行。实际上，在加热过程中，(甲基)丙烯酸类热塑性聚合物材料可以例如以(甲基)丙烯酸类热塑性聚合物制成的棒的形式来提供。当设置两个由热塑性聚合物复合材料制成的部件的步骤120过程中形成中空或空的空间时，这是有利的。经由(甲基)丙烯酸类热塑性聚合物制成的棒来供应热塑性填充材料能够填充任何中空或空间。
优选地，在加热步骤230的过程中，组装界面11处的温度为160至300℃。该温度可以通过红外测温仪常规地测量。
图3A和3B显示了根据本发明的方法组装的窗型材的两个部件20的纵向截面的以顶视图显示的两个简化图示。在图3A中，由热塑性聚合物复合材料制成的窗型材的两个部件20被热板24隔开。当达到熔点时，移除热板24，使热塑性聚合物复合材料制成的窗型材的两个部件20彼此接触（参见图3B），从而形成包含焊接界面22的热塑性聚合物复合材料制成的窗型材2。
施加压力的任选步骤140包括在组装界面11处产生压力。在加热步骤130后产生的这种压力能够增强所述至少两个由聚合物复合材料制成的部件10之间的焊接界面，从而形成包含焊接界面12的由热塑性聚合物复合材料制成的物体。所述两个由热塑性聚合物复合材料制成的部件10还可以以所需位置或形式坚固地连接在一起并保持到热塑性聚合物基质冷却，由此形成牢固的焊接界面12。该压力例如可以通过在组装11至少两个由热塑性聚合物复合材料制成的部件10的区域处施加局部真空来产生。也可以通过施加基本上垂直于组装界面区域11的力来产生压力，例如通过将模板堆积在所述至少两个由热塑性聚合物复合材料制成的部件上。
任选的冷却步骤150能够改善该焊接界面12的机械性质。这种冷却步骤150可以在室温（例如15℃至25℃）下进行，或在低于该(甲基)丙烯酸类热塑性聚合物的Tg的温度下进行。
根据第二方面，本发明涉及由至少两个由热塑性聚合物复合材料制成的部件10制造的由热塑性聚合物复合材料制成的物体。如上所述，该热塑性聚合物复合材料包含纤维增强材料和(甲基)丙烯酸类热塑性聚合物基质，并且所述至少两个由热塑性聚合物复合材料制成的部件10通过焊接界面12连接。本发明的热塑性聚合物复合材料制成的物体可以用于许多领域，优选用于建筑、航空、航海、汽车和休闲领域。由此，本发明的由热塑性聚合物复合材料制成的物体可以优选选自由多个板组成的包覆物、栏杆、窗型材、飞机机身、建筑的加固件、横梁（尤其用于车辆）、用于车辆的白车身部件、吊舱、尾翼、肋片、扰流板、襟翼、船用涡轮叶片、船体、船桥、船用舱壁和用于汽车的饰板（罩）。
在说明书的剩余部分中，给出了物体的三种其它实例。
图4A和4B描述了由本发明的热塑性聚合物复合材料制成的物体3、4。图4A描述了用于汽车的保险杠加强型的横梁3，其由本发明的热塑性聚合物复合材料制成，包含焊接界面32。由热塑性聚合物复合材料制成的这些部件30构成了用于车辆的结构元件，并通过多个焊接界面32来连接。本发明不限于这些特定部件30，还可以在制造构成例如车体如车身、地板、挡泥板、门、如图4B中所示的连接后轮系的横梁40的其它部件中实施。
图5描绘了飞机机身部分5，其包含由热塑性聚合物复合材料制成的多个机身部件50，其中一些包含(甲基)丙烯酸类热塑性聚合物的层53。
此外，优选地，本发明的由热塑性聚合物复合材料制成的物体1、2、3、4、5不包含超过50重量%、更优选不超过40重量%、更优选不超过30重量%、有利地不超过20重量%、更有利地不超过15重量%和甚至更有利地不超过10重量%的热固性聚合物，如环氧或聚酯或聚氨酯树脂。然而，迄今为止，热固性聚合物通常用于制造由聚合物复合材料制成的物体1。同样地，本发明的由热塑性聚合物复合材料制成的物体1优选不包含超过10重量%、更优选不超过9重量%和甚至更优选不超过8重量%、有利地不超过7重量%、更有利地不超过6重量%和甚至更有利地不超过5重量%的粘合剂、优选热固性粘合剂。实际上，由聚合物复合材料制成的不同物体部件的粘合剂粘结通常用环氧树脂类型的热固性结构粘合剂来进行。
优选地，本发明的部件10、20、30、40、50的热塑性聚合物复合材料至少部分覆盖有至少0.5 mm、优选至少1 mm、更优选至少2 mm厚的(甲基)丙烯酸类热塑性聚合物层，例如在意在被焊接的表面上。该聚合物复合材料更特别地在意在形成未来的焊接界面12的组装界面区域处覆盖有(甲基)丙烯酸类热塑性聚合物的层。这尤其能够避免出现具有较低浓度的热塑性聚合物的区域。或者，由热塑性聚合物复合材料制成的部件10、20、30、40、50可以具有至少一个覆盖有(甲基)丙烯酸类热塑性聚合物层的面。
特别有利地，本发明的由聚合物复合材料制成的物体1、2、3、4、5包含长度大于1米，优选大于5米的焊接界面12、22、32、42。
在本发明的上下文中，使用由包含纤维增强材料和(甲基)丙烯酸类热塑性聚合物基质的热塑性聚合物复合材料制成的部件10能够显著减少聚合物复合材料制成的物体1、2、3、4、5中所用的热固性聚合物的量，并开辟了采用热固性材料无法设想的可能性，如大部分热塑性聚合物复合材料制成的物体1、2、3、4、5的回收，以及更容易的组装或维修。

Claims (29)

1.由至少两个由热塑性聚合物复合材料制成的部件（10）来制造由热塑性聚合物复合材料制成的物体（1）的方法（100），所述热塑性聚合物复合材料包含纤维增强材料和热塑性聚合物基质，所述方法包括以下步骤：
- 在组装界面区域（11）处相邻或重叠布置（120）两个由热塑性聚合物复合材料制成的部件（10），
- 在所述组装界面区域（11）处加热（130）以熔融所述热塑性聚合物基质，从而形成包含焊接界面（12）的由热塑性聚合物复合材料制成的物体（1）。
2.如权利要求1所要求保护的制造方法，其特征在于所述至少两个由热塑性聚合物复合材料制成的部件是由(甲基)丙烯酸类热塑性聚合物复合材料制成的部件。
3.如权利要求1或2所要求保护的制造方法，其特征在于其包括制造（110）至少两个由(甲基)丙烯酸类热塑性聚合物复合材料制成的部件（10）的在先步骤，所述(甲基)丙烯酸类热塑性聚合物复合材料包含纤维增强材料和(甲基)丙烯酸类热塑性聚合物基质。
4.如权利要求1至3任一项所要求保护的制造方法，其特征在于所述纤维增强材料包含单独或混合物形式的选自碳纤维或玻璃纤维或玄武岩纤维或基于聚合物的纤维或植物纤维的纤维。
5.如权利要求1至4任一项所要求保护的制造方法，其特征在于所述纤维增强材料基于纵横比为至少1000的纤维。
6.如权利要求1至5任一项所要求保护的制造方法，其特征在于其在加热步骤（130）之后还包括在界面处施加（140）压力的步骤，以便将至少两个由热塑性聚合物复合材料制成的部件（10）焊接在一起。
7.如权利要求2至6任一项所要求保护的制造方法，其特征在于所述(甲基)丙烯酸类热塑性聚合物选自聚(甲基丙烯酸甲酯)（PMMA）或甲基丙烯酸甲酯（MMA）的共聚物，或其混合物。
8.如权利要求2至7任一项所要求保护的制造方法，其特征在于所述(甲基)丙烯酸类热塑性聚合物具有50℃至160℃的玻璃化转变温度（Tg）。
9.如权利要求2至8任一项所要求保护的制造方法，其特征在于所述(甲基)丙烯酸类热塑性聚合物基质还包含一种或多种添加剂或填料。
10.如权利要求3至9任一项所要求保护的制造方法，其特征在于制造（110）至少两个由(甲基)丙烯酸类热塑性聚合物复合材料制成的部件（10）的步骤包括以下子步骤：
- 用液体(甲基)丙烯酸类组合物浸渍（111）纤维增强材料，
- 聚合（112）所述液体(甲基)丙烯酸类组合物。
11.如权利要求10所要求保护的制造方法，其特征在于所述液体(甲基)丙烯酸类组合物包含(甲基)丙烯酸类单体、前体(甲基)丙烯酸类聚合物和自由基引发剂。
12.如权利要求10所要求保护的制造方法，其特征在于所述液体(甲基)丙烯酸类组合物包含(甲基)丙烯酸类单体或(甲基)丙烯酸类单体的混合物、前体(甲基)丙烯酸类聚合物。
13.如权利要求11或12所要求保护的制造方法，其特征在于所述液体(甲基)丙烯酸类组合物或所述液体(甲基)丙烯酸类浆液中(甲基)丙烯酸类单体或(甲基)丙烯酸类单体的混合物以液体(甲基)丙烯酸类组合物中至少40重量%、优选至少45重量%、更优选至少50重量%、有利地为至少60重量%和更有利地为至少65重量%的量存在。
14.如权利要求11或12所要求保护的制造方法，其特征在于所述液体(甲基)丙烯酸类组合物或所述液体(甲基)丙烯酸类浆液中的前体(甲基)丙烯酸类聚合物以液体(甲基)丙烯酸类组合物中至少10重量%、优选至少15重量%、有利地为至少18重量%和更有利地为至少20重量%的量存在。
15.如权利要求11或12所要求保护的制造方法，其特征在于所述液体(甲基)丙烯酸类组合物或所述液体(甲基)丙烯酸类浆液中的前体(甲基)丙烯酸类聚合物以液体(甲基)丙烯酸类组合物中至多60重量%、优选至多50重量%、有利地为至多40重量%和更有利地为至多35重量%的量存在。
16.如权利要求11或12所要求保护的制造方法，其特征在于，在所述液体(甲基)丙烯酸类组合物中，所述化合物以下列重量百分比混入：
• 所述液体组合物或所述(甲基)丙烯酸类浆液中的(甲基)丙烯酸类单体以(甲基)丙烯酸类单体和(甲基)丙烯酸类聚合物所组成的组合物的40重量%至90重量%和优选45重量%至85重量%的比例存在，
• 所述液体组合物或所述(甲基)丙烯酸类浆液中的(甲基)丙烯酸类聚合物以一种或多种(甲基)丙烯酸类单体和(甲基)丙烯酸类聚合物所组成的组合物的10重量%至60重量%和有利地为15重量%至55重量%的比例存在；优选地，所述液体组合物中的(甲基)丙烯酸类聚合物以(甲基)丙烯酸类单体和(甲基)丙烯酸类聚合物所组成的组合物的18重量%至30重量%、更优选20重量%至25重量%的比例存在。
17.如权利要求1至16任一项所要求保护的制造方法，其特征在于由热塑性聚合物复合材料制成的部件（10）在小于150℃、优选小于100℃的温度下制造。
18.如权利要求1至17任一项所要求保护的制造方法，其特征在于由热塑性聚合物复合材料制成的部件（10）通过低压注塑、灌注成型或通过模塑用(甲基)丙烯酸类热塑性聚合物复合材料预浸渍的条带来制造。
19.如权利要求1至18任一项所要求保护的制造方法，其特征在于所述两个由热塑性聚合物复合材料制成的部件（10）中的至少一个在意在被焊接的表面上包含至少0.5 mm厚的(甲基)丙烯酸类热塑性聚合物层（13）。
20.如权利要求1至19任一项所要求保护的制造方法，其特征在于，在加热步骤过程中，焊接界面（11）处的温度为160至300℃。
21.如权利要求1至20任一项所要求保护的制造方法，其特征在于所述热塑性聚合物基质通过选自以下的技术来熔融（130）：超声波焊接、感应焊接、电阻丝焊接、搅拌摩擦焊接、激光焊接、通过红外或紫外辐射加热，和优选通过电阻丝焊接。
22.如权利要求1至21任一项所要求保护的制造方法，其特征在于所述两个由热塑性聚合物复合材料制成的部件（10）中的至少一个包含至少一个位于组装界面（11）处的电阻丝。
23.由至少两个由聚合物复合材料制成的部件（10）制造的由聚合物复合材料制成的物体（1），其特征在于所述热塑性聚合物复合材料包含纤维增强材料和热塑性聚合物基质、优选(甲基)丙烯酸类热塑性聚合物基质，并且在于所述至少两个由热塑性聚合物复合材料制成的部件（10）通过焊接界面（12）来连接。
24.如权利要求23所要求保护的由聚合物复合材料制成的物体，其特征在于其不包含超过50重量%、优选不超过30重量%的热固性聚合物。
25.如权利要求23所要求保护的由聚合物复合材料制成的物体，其特征在于其不包含超过15重量%、优选不超过10重量%的热固性聚合物。
26.如权利要求23、24或25之一所要求保护的由聚合物复合材料制成的物体，其特征在于其不包含超过10重量%、优选不超过8重量%的粘合剂，优选热固性粘合剂。
27.如权利要求23、24或25之一所要求保护的由聚合物复合材料制成的物体，其特征在于其不包含超过6重量%、优选不超过5重量%的热固性粘合剂。
28.如权利要求23至27的任一项所要求保护的由聚合物复合材料制成的物体，其特征在于所述(甲基)丙烯酸类热塑性聚合物选自聚(甲基丙烯酸甲酯)（PMMA）或甲基丙烯酸甲酯（MMA）的共聚物，或其混合物。
29.如权利要求23至28的任一项所要求保护的由聚合物复合材料制成的物体，其特征在于其选自：由多个板组成的包覆物、栏杆、窗型材、飞机机身、建筑的加固件、横梁尤其用于车辆的横梁、白车身部件、吊舱、尾翼、肋片、扰流板、襟翼、船用涡轮叶片、船体、船桥、船用舱壁和用于汽车的饰板（罩）。
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TWI837536B (zh) * 2020-11-11 2024-04-01 英商科伊斯有限公司 結構性殼體
CN116529058A (zh) * 2020-11-13 2023-08-01 西门子歌美飒可再生能源创新与技术有限公司 一种用于生产风力涡轮机的转子叶片的方法
US12420492B2 (en) 2020-11-13 2025-09-23 Siemens Gamesa Renewable Energy Innovation & Technology S.L. Method for producing a rotor blade of a wind turbine
CN113043604A (zh) * 2021-02-04 2021-06-29 东华大学 具有高焊接强度的热塑性复合材料含植入层感应焊接方法
CN118124207A (zh) * 2024-04-07 2024-06-04 山东宽原新材料科技有限公司 一种碳纤维热塑性复合材料物化共固连接成型方法

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BR112019018837B1 (pt) 2023-03-28
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FR3063672B1 (fr) 2022-07-01
JP2020510559A (ja) 2020-04-09
KR20190121845A (ko) 2019-10-28
FR3063672A1 (fr) 2018-09-14
EP3595873A1 (fr) 2020-01-22
US11623412B2 (en) 2023-04-11
WO2018172657A1 (fr) 2018-09-27
BR112019018837A2 (pt) 2020-04-14
MX2019010639A (es) 2019-10-17
US20200047427A1 (en) 2020-02-13

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