EP1372940A1 - Method of producing a thick, thermoformable, fiber-reinforced semi-finished product - Google Patents
Method of producing a thick, thermoformable, fiber-reinforced semi-finished productInfo
- Publication number
- EP1372940A1 EP1372940A1 EP02727385A EP02727385A EP1372940A1 EP 1372940 A1 EP1372940 A1 EP 1372940A1 EP 02727385 A EP02727385 A EP 02727385A EP 02727385 A EP02727385 A EP 02727385A EP 1372940 A1 EP1372940 A1 EP 1372940A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- fibers
- thermoplastic
- finished product
- semi
- reinforcing fibers
- 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.)
- Withdrawn
Links
- 239000011265 semifinished product Substances 0.000 title claims abstract description 24
- 238000000034 method Methods 0.000 title claims abstract description 21
- 239000000835 fiber Substances 0.000 claims abstract description 29
- 229920001169 thermoplastic Polymers 0.000 claims abstract description 26
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract description 26
- 239000012783 reinforcing fiber Substances 0.000 claims abstract description 22
- 238000004519 manufacturing process Methods 0.000 claims description 11
- -1 polypropylene Polymers 0.000 claims description 6
- 239000004743 Polypropylene Substances 0.000 claims description 5
- 229920001155 polypropylene Polymers 0.000 claims description 5
- 238000009960 carding Methods 0.000 claims description 4
- 238000010924 continuous production Methods 0.000 claims description 3
- 238000009499 grossing Methods 0.000 claims description 3
- 238000010030 laminating Methods 0.000 claims description 3
- 239000002346 layers by function Substances 0.000 claims description 3
- 239000000155 melt Substances 0.000 claims description 3
- 239000003365 glass fiber Substances 0.000 claims description 2
- 230000005855 radiation Effects 0.000 claims description 2
- 230000002787 reinforcement Effects 0.000 claims 1
- 239000012815 thermoplastic material Substances 0.000 abstract description 3
- 238000011437 continuous method Methods 0.000 abstract 1
- 238000010438 heat treatment Methods 0.000 abstract 1
- 238000002156 mixing Methods 0.000 abstract 1
- 238000009952 needle felting Methods 0.000 abstract 1
- 238000007596 consolidation process Methods 0.000 description 4
- 239000011521 glass Substances 0.000 description 4
- 239000004760 aramid Substances 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 230000003014 reinforcing effect Effects 0.000 description 2
- 239000002002 slurry Substances 0.000 description 2
- 239000004753 textile Substances 0.000 description 2
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000004809 Teflon Substances 0.000 description 1
- 229920006362 Teflon® Polymers 0.000 description 1
- 239000004433 Thermoplastic polyurethane Substances 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 229920003235 aromatic polyamide Polymers 0.000 description 1
- 239000012752 auxiliary agent Substances 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000009950 felting Methods 0.000 description 1
- 238000007731 hot pressing Methods 0.000 description 1
- 239000010410 layer Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 229920001643 poly(ether ketone) Polymers 0.000 description 1
- 229920002492 poly(sulfone) Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920001230 polyarylate Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920001601 polyetherimide Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920006324 polyoxymethylene Polymers 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 239000002351 wastewater Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
- D04H1/4218—Glass fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
- B29C70/465—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating by melting a solid material, e.g. sheets, powders of 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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C70/504—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands
- B29C70/506—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands and impregnating by melting a solid material, e.g. sheet, powder, fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
- D04H1/485—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
Definitions
- the invention relates to a method for producing a thick, thermoplastically deformable, fiber-reinforced semi-finished product from a mixed fleece, which contains thermoplastic fibers and reinforcing fibers.
- Thermoplastic deformable semi-finished products which contain reinforcing fibers, in particular glass mats, are increasingly used for the production of molded parts, in particular for motor vehicle parts.
- Such "plastic sheets” are characterized by high toughness and strength.
- These GMT semifinished products are produced on an industrial scale by bringing together continuous glass mats and thermoplastic melt webs on a double belt press.
- this method of operation requires a high amount of energy because the viscous melt flows into the This means that fiber contents of more than 50% by weight can hardly be achieved. Since the glass mats are generally made up of fiber bundles, the impregnation is never completely and evenly, so that microscopically inhomogeneous areas occur, which leads to high standard deviations in mechanical properties.
- Another, technically applied process is based on paper production.
- Thermoplastic fibers and reinforcing fibers are mixed together as an aqueous slurry, the slurry is squeezed out and the mixed fleece obtained is dried and hot-pressed. Large amounts of water have to be handled here and the waste water contaminated with auxiliary agents has to be cleaned.
- DE-A 36 14 533 describes a process for the production of moldings from thermoplastic materials which contain a reinforcing insert, described.
- a mixed nonwoven made of thermoplastic fibers and reinforcing fibers is manufactured according to the carding or airlay process and consolidated by needles, for example. Blanks from this mixed fleece are heated and pressed directly into three-dimensional shaped bodies without prior consolidation. Complete impregnation is hardly possible, especially in the case of components with a complicated shape, so that the mechanical properties of the molded parts leave something to be desired.
- EP-A 555 345 describes an air-permeable fiber structure made from a wet or dry mixed fleece made of thermoplastic fibers and reinforcing fibers. This non-needled mixed fleece is partially consolidated by carefully melting the thermoplastic fibers by connecting them to the reinforcing fibers at the crossing points. A continuous production of the fiber structure is not described. The process also has the disadvantage that the non-wetted reinforcing fibers can corrode during storage, and complete soaking is also difficult here in the production of molded articles.
- German patent application P 101 05 813.6 describes a process for producing a thermoplastic, fiber-reinforced semi-finished product with a thickness of 0.2 to 3.0 mm, in which a mixed nonwoven made of thermoplastic fibers and 30 to 300 mm long reinforcing fibers is needled, heated and is pressed on a calender or in a smoothing unit. If you want to press finished parts with a complicated three-dimensional shape from this relatively thin semi-finished product, especially those that have filigree ribs, you will find that the ribs are not satisfactorily filled with fibers. With a thicker semi-finished product, one should assume that the flowability is improved.
- the invention was based on the object of developing a continuous process for producing a relatively thick semifinished product from a thermoplastic and reinforcing fibers which can be formed into finished parts which have excellent, easily reproducible mechanical properties in all directions. This object is achieved by the method according to the invention. This includes the following process steps:
- thermoplastic fibers and individual, non-bonded synthetic reinforcing fibers are dry mixed together using the carding or airlay process.
- All spinnable thermoplastic materials are suitable as thermoplastics, for example polyolefins, such as polyethylene and polypropylene, polyamides, linear polyesters, thermoplastic polyurethanes, polycarbonate, polyacetals, and corresponding copolymers and mixtures, and also high-temperature-resistant polymers, such as polyarylates, polysulfones, polyetherimides, polyimides and polyether ketones. Polypropylene is particularly preferred.
- the corresponding fibers can be produced by spinning the thermoplastic melts or solutions.
- the thermoplastic fibers generally have an average length of 10 to 200 mm.
- the melt index of the thermoplastic should be relatively high.
- the MFI 230 ° C, 2.16 kp
- the MFI greater than 300 g / 10 min according to DIN 53735 and preferably between 400 and 1000 g / 10 min.
- Preferred reinforcing fibers are glass fibers; in addition, carbon fibers and aramid fibers can also be used in principle.
- the reinforcing fibers used have an average length of 20 to 80 mm, preferably of 25 to 50 mm. Such short fibers also flow into thin areas of the tool during pressing. In order for them to be readily miscible with the thermoplastic fibers, they must be present as individual, unbound fibers, i.e. they must not be bound with polymeric binders.
- thermoplastic fibers and reinforcing fibers are dry mixed in a weight ratio of 10:90 to 80:20, preferably 25:75 to 55:45 by the carding or airlay method, as are known from textile technology. This creates a mixed fleece that is present as an endless web.
- the mixed fleece obtained is consolidated by needling. This can be done on standard needle chairs with felting needles. Needling breaks the reinforcing fibers somewhat, so that the average fiber length is reduced; on the other hand, individual fibers are pulled through the fleece so that they are aligned perpendicular to the main surface and can have a reinforcing effect in this direction in the finished part. In addition, these vertically directed fibers cause the semi-finished product to expand in the z direction when heated. This so-called "loft" can be used for the production of lightweight components by partial consolidation. Finally, the mixed fleece is consolidated by the needling according to the invention, so that it can be handled without problems in the subsequent process steps. In a special embodiment of the invention, the needled mixed nonwoven is stretched in one direction. As a result, the reinforcing fibers in the finished part are aligned in this direction and thus bring about a particularly high mechanical level in this direction.
- the solidified mixed fleece is heated in the forced air oven or by IR radiation to temperatures above the softening temperature of the thermoplastic.
- the temperature should preferably be 20 to 60 ° C above the softening temperature; in the case of polypropylene fibers, it is preferably between 180 and 220 ° C., in particular between 190 and 210 ° C.
- a laminating device is a double belt press, which - in contrast to conventional GMT double belt presses - does not have steel belts, but rather belts made of polymer, preferably Teflon-coated glass or aramid fabric, and where work is carried out with significantly lower pressures between 1 and 10 bar.
- the resulting flat semifinished product according to the invention has a thickness of more than 3.0 mm, preferably from 3.2 to 10.0 mm.
- the average length of the reinforcing fibers in the semifinished product is 10 to 60 mm, preferably the fibers are on average less than 50 mm long.
- functional layers are brought to the heated mixed fleece on one or both sides and pressed together.
- the functional layers can also only be applied during the production of the molded part.
- the semi-finished product produced according to the invention can be cut into customer-specific blanks and stacked on pallets and shipped. It can then be thermoformed into three-dimensional finished parts. For this purpose, corresponding blanks are heated to temperatures above the softening temperature of the thermoplastic and pressed in conventional two-part molds or deformed by deep drawing.
- the semi-finished product is relatively thick and contains short fibers, these also flow into fine areas of the tool during pressing, so that finished parts with a complicated spatial shape and in particular with filigree ribs can be produced.
- the finished parts can be used in the transport sector as automotive, railway and aircraft interior parts, but also as body parts, as large-area panels and as furniture parts.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Textile Engineering (AREA)
- Composite Materials (AREA)
- Inorganic Chemistry (AREA)
- Nonwoven Fabrics (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
Abstract
Description
Verfahren zur Herstellung eines dicken, thermoplastisch verformbaren, faserverstärkten Halbzeugs Process for the production of a thick, thermoplastically deformable, fiber-reinforced semi-finished product
Die Erfindung betrifft ein Verfahren zur Herstellung eines dicken, thermoplastisch verformbaren, faserverstärkten Halbzeugs aus einem Mischvlies, welches Thermoplastfasern und Verstärkungsfasern enthält.The invention relates to a method for producing a thick, thermoplastically deformable, fiber-reinforced semi-finished product from a mixed fleece, which contains thermoplastic fibers and reinforcing fibers.
Thermoplastisch verformbare Halbzeuge, welche Verstärkungsfasern, insbesondere Glasmatten enthalten, werden in zunehmendem Maße zur Herstellung von Formteilen, insbesondere für Kraftfahrzeugteile eingesetzt. Derartige „Kunststoffbleche" zeichnen sich durch hohe Zähigkeit und Festigkeit aus. Diese GMT-Halbzeuge werden in großtechnischem Maßstab hergestellt durch Zusammenführen von Endlos-Glasmatten und Thermoplast-Schmelzebahnen auf einer Doppelbandpresse. Diese Arbeitsweise erfordert jedoch einen hohen Energieaufwand, da die zähflüssige Schmelze in die Matte eingepreßt werden muß. Fasergehalte von mehr als 50 Gew.-% sind so kaum erreichbar. Da die Glasmatten im allgemeinen aus Faserbündeln aufgebaut sind, ist die Tränkung nie ganz vollständig und gleichmäßig, so daß mikroskopisch inhomogene Bereiche auftreten, was zu hohen Standardabweichungen in den mechanischen Eigenschaften führt.Thermoplastic deformable semi-finished products, which contain reinforcing fibers, in particular glass mats, are increasingly used for the production of molded parts, in particular for motor vehicle parts. Such "plastic sheets" are characterized by high toughness and strength. These GMT semifinished products are produced on an industrial scale by bringing together continuous glass mats and thermoplastic melt webs on a double belt press. However, this method of operation requires a high amount of energy because the viscous melt flows into the This means that fiber contents of more than 50% by weight can hardly be achieved. Since the glass mats are generally made up of fiber bundles, the impregnation is never completely and evenly, so that microscopically inhomogeneous areas occur, which leads to high standard deviations in mechanical properties.
Ein anderes, technisch angewandtes Verfahren lehnt sich an die Papierherstellung an. Thermoplastfasern und Verstärkungsfasern werden als wäßrige Aufschläm- mung miteinander vermischt, die Aufschlämmung wird abgepreßt und das erhaltene Mischvlies wird getrocknet und heiß verpreßt. Hier muß mit großen Mengen Wasser hantiert werden und das mit Hilfsmitteln verunreinigte Abwasser muß gereinigt werden.Another, technically applied process is based on paper production. Thermoplastic fibers and reinforcing fibers are mixed together as an aqueous slurry, the slurry is squeezed out and the mixed fleece obtained is dried and hot-pressed. Large amounts of water have to be handled here and the waste water contaminated with auxiliary agents has to be cleaned.
In der DE-A 36 14 533 ist ein Verfahren zur Herstellung von Formkörpern aus thermoplastischen Kunststoffen, die eine Verstärkungseinlage enthalten, beschrieben. Dabei wird in Anlehnung an die Textilfasertechnologie ein Mischvlies aus Thermoplastfasern und Verstärkungsfasern nach dem Krempel- oder Airlay- Verfahren hergestellt und z.B. durch Nadeln verfestigt. Zuschnitte aus diesem Mischvlies werden erwärmt und direkt, ohne vorheriges Konsolidieren, zu dreidimensionalen Formkörpern verpreßt. Eine vollständige Durchtränkung ist hierbei, vor allem bei kompliziert geformten Bauteilen, jedoch kaum möglich, so daß die mechanischen Eigenschaften der Formteile zu wünschen übrig lassen.DE-A 36 14 533 describes a process for the production of moldings from thermoplastic materials which contain a reinforcing insert, described. Based on textile fiber technology, a mixed nonwoven made of thermoplastic fibers and reinforcing fibers is manufactured according to the carding or airlay process and consolidated by needles, for example. Blanks from this mixed fleece are heated and pressed directly into three-dimensional shaped bodies without prior consolidation. Complete impregnation is hardly possible, especially in the case of components with a complicated shape, so that the mechanical properties of the molded parts leave something to be desired.
Die Herstellung eines konsolidierten Halbzeugs mit einer Dicke von 1,25 bis 2,5 mm ist in US-A 4,948,661 beschrieben. Zunächst wird in einem Trockenverfahren ein Mischvlies aus Thermoplastfasern und Verst rkungsfasern hergestellt. Dieses Mischvlies wird jedoch nicht vernadelt, sondern wellenförmig zusammengefaltet und direkt durch Heißverpressen zum Halbzeug konsolidiert. Infolge der fehlenden Verfestigung des Mischvlieses ist das Konsolidieren in der Praxis problemlos nur diskontinuierlich möglich. Ein kontinuierliches Konsolidieren auf einer Doppelbandpresse wird zwar auch erwähnt, dabei würden aber - wenn es überhaupt praktisch durchführbar ist - die oben beschriebenen Nachteile auftreten.The production of a consolidated semi-finished product with a thickness of 1.25 to 2.5 mm is described in US-A 4,948,661. First, a mixed fleece is made from thermoplastic fibers and reinforcing fibers in a dry process. However, this mixed fleece is not needled, but folded together in a wave shape and consolidated directly into the semi-finished product by hot pressing. Due to the lack of solidification of the mixed fleece, consolidation in practice is only possible intermittently without any problems. Continuous consolidation on a double belt press is also mentioned, but the disadvantages described above would occur, if it is practicable at all.
Schließlich beschreibt die EP-A 555 345 ein luftdurchlässiges Fasergebilde aus einem naß oder trocken hergestellten Mischvlies aus Thermoplastfasern und Verstärkungsfasern. Dieses nicht vernadelte Mischvlies wird durch vorsichtiges Anschmelzen der Thermoplastfasern teilverfestigt, indem diese sich an den Kreuzungsstellen mit den Verstärkungsfasern verbinden. Eine kontinuierliche Herstellung des Fasergebildes ist nicht beschrieben. Das Verfahren hat darüber hinaus den Nachteil, daß die nicht benetzten Verstärkungsfasern bei der Lagerung korrodieren können, außerdem ist auch hier bei der Formkörperherstellung eine vollständige Durchtränkung schwierig. In der deutschen Patentanmeldung P 101 05 813.6 ist ein Verfahren zur Herstellung eines thermoplastisch verformbaren, faserverstärkten Halbzeugs mit einer Dicke von 0,2 bis 3,0 mm beschrieben, bei dem ein Mischvlies aus Thermoplastfasern und 30 bis 300 mm langen Verstärkungsfasern vernadelt, erwärmt und auf einem Kalander oder in einem Glättwerk verpreßt wird. Wenn man aus diesem relativ dünnen Halbzeug Fertigteile mit komplizierter Raumform pressen will, insbesondere solche, die filigrane Rippen aufweisen, dann stellt man fest, daß die Rippen nicht zufriedenstellend mit Fasern gefüllt sind. Bei einem dickeren Halbzeug sollte man annehmen, daß die Fließfähigkeit verbessert ist.Finally, EP-A 555 345 describes an air-permeable fiber structure made from a wet or dry mixed fleece made of thermoplastic fibers and reinforcing fibers. This non-needled mixed fleece is partially consolidated by carefully melting the thermoplastic fibers by connecting them to the reinforcing fibers at the crossing points. A continuous production of the fiber structure is not described. The process also has the disadvantage that the non-wetted reinforcing fibers can corrode during storage, and complete soaking is also difficult here in the production of molded articles. German patent application P 101 05 813.6 describes a process for producing a thermoplastic, fiber-reinforced semi-finished product with a thickness of 0.2 to 3.0 mm, in which a mixed nonwoven made of thermoplastic fibers and 30 to 300 mm long reinforcing fibers is needled, heated and is pressed on a calender or in a smoothing unit. If you want to press finished parts with a complicated three-dimensional shape from this relatively thin semi-finished product, especially those that have filigree ribs, you will find that the ribs are not satisfactorily filled with fibers. With a thicker semi-finished product, one should assume that the flowability is improved.
Der Erfindung lag nun die Aufgabe zugrunde, ein kontinuierliches Verfahren zur Herstellung eines relativ dicken Halbzeugs aus einem thermoplastischen Kunststoff und Verstärkungsfasern zu entwickeln, das zu Fertigteilen umformbar ist, die in allen Richtungen hervorragende, gut reproduzierbare mechanische Eigenschaften aufweisen. Diese Aufgabe wird durch das erfindungsgemäße Verfahren gelöst. Dieses umfaßt folgende Verfahrensschritte:The invention was based on the object of developing a continuous process for producing a relatively thick semifinished product from a thermoplastic and reinforcing fibers which can be formed into finished parts which have excellent, easily reproducible mechanical properties in all directions. This object is achieved by the method according to the invention. This includes the following process steps:
A. Thermoplastfasern und individuelle, nicht gebundene synthetische Verstärkungsfasern werden nach dem Krempel- oder Airlay-Verfahren trocken miteinander vermischt. Als Thermoplasten kommen alle verspinnbare thermoplastische Kunststoffe in Frage, z.B. Polyolefine, wie Polyethylen und Polypropylen, Polyamide, lineare Polyester, thermoplastische Polyurethane, Polycarbonat, Polyacetale, sowie entsprechende Copolymere und Mischungen, ferner hochtemperaturbeständige Polymere, wie Polyarylate, Poly- sulfone, Polyetherimide, Polyimide und Polyetherketone. Besonders bevorzugt ist Polypropylen. Die entsprechenden Fasern lassen sich durch Verspinnen der Thermoplastschmelzen oder -lösungen herstellen. Die Thermoplastfasern weisen im allgemeinen eine mittlere Länge von 10 bis 200 mm auf. Damit das Halbzeug gut fließfähig ist, sollte der Schmelzindex des Thermoplasten relativ hoch sein. Im Fall von Polypropylen sollte der MFI (230°C, 2.16 kp) nach DIN 53735 größer als 300 g/10 min sein und vorzugsweise zwischen 400 und 1000 g/10min liegen.A. Thermoplastic fibers and individual, non-bonded synthetic reinforcing fibers are dry mixed together using the carding or airlay process. All spinnable thermoplastic materials are suitable as thermoplastics, for example polyolefins, such as polyethylene and polypropylene, polyamides, linear polyesters, thermoplastic polyurethanes, polycarbonate, polyacetals, and corresponding copolymers and mixtures, and also high-temperature-resistant polymers, such as polyarylates, polysulfones, polyetherimides, polyimides and polyether ketones. Polypropylene is particularly preferred. The corresponding fibers can be produced by spinning the thermoplastic melts or solutions. The thermoplastic fibers generally have an average length of 10 to 200 mm. In order for the semi-finished product to flow well, the melt index of the thermoplastic should be relatively high. In the case of polypropylene, the MFI (230 ° C, 2.16 kp) greater than 300 g / 10 min according to DIN 53735 and preferably between 400 and 1000 g / 10 min.
Bevorzugte Verstärkungsfasern sind Glasfasern, daneben können grundsätzlich auch Kohlenstoffasem und Aramidfasem eingesetzt werden. Die eingesetzten Verstärkungsfasern weisen eine mittlere Länge von 20 bis 80 mm, vorzugsweise von 25 bis 50 mm auf. Derart kurze Fasern fließen beim Verpressen auch in dünne Bereiche des Werkzeugs. Damit sie gut mit den Thermoplastfasern mischbar sind, müssen sie als individuelle, nicht gebundene Fasern vorliegen, d.h. sie dürfen nicht mit polymeren Bindemitteln gebunden sein.Preferred reinforcing fibers are glass fibers; in addition, carbon fibers and aramid fibers can also be used in principle. The reinforcing fibers used have an average length of 20 to 80 mm, preferably of 25 to 50 mm. Such short fibers also flow into thin areas of the tool during pressing. In order for them to be readily miscible with the thermoplastic fibers, they must be present as individual, unbound fibers, i.e. they must not be bound with polymeric binders.
Die Thermoplastfasern und Verstärkungsfasern werden im Gewichtsverhältnis 10 : 90 bis 80 : 20, vorzugsweise 25 : 75 bis 55 : 45 nach dem Krempeloder Airlay- Verfahren, wie sie aus der Textiltechnologie bekannt sind, trocken miteinander vermischt. Dabei entsteht ein als endlose Bahn vorliegendes Mischvlies.The thermoplastic fibers and reinforcing fibers are dry mixed in a weight ratio of 10:90 to 80:20, preferably 25:75 to 55:45 by the carding or airlay method, as are known from textile technology. This creates a mixed fleece that is present as an endless web.
Das erhaltene Mischvlies wird durch Nadeln verfestigt. Dies kann auf üblichen Nadelstühlen mit Filznadeln geschehen. Durch das Nadeln werden einerseits die Verstärkungsfasern etwas gebrochen, so daß die mittlere Faserlänge reduziert wird; andererseits werden einzelne Fasern durch das Vlies hindurchgezogen, so daß sie senkrecht zur Hauptfläche ausgerichtet werden und im Fertigteil in dieser Richtung verstärkend wirken können. Außerdem bewirken diese senkrecht gerichteten Fasern, daß das Halbzeug beim Aufheizen in z-Richtung expandiert. Dieser sogenannte „Loft" kann zur Herstellung von Leichtbauteilen durch Teilkonsolidieren ausgenützt werden. Schließlich wird durch das erfindungsgemäße Nadeln das Mischvlies verfestigt, so daß es in den nachfolgenden Verfahrensschritten problemlos handhabbar ist. Bei einer speziellen Ausführungsform der Erfindung wird das genadelte Mischvlies in einer Richtung verstreckt. Dadurch sind auch im Fertigteil die Verstärkungsfasern in dieser Richtung ausgerichtet und bewirken so ein besonders hohes mechanisches Niveau in dieser Richtung.The mixed fleece obtained is consolidated by needling. This can be done on standard needle chairs with felting needles. Needling breaks the reinforcing fibers somewhat, so that the average fiber length is reduced; on the other hand, individual fibers are pulled through the fleece so that they are aligned perpendicular to the main surface and can have a reinforcing effect in this direction in the finished part. In addition, these vertically directed fibers cause the semi-finished product to expand in the z direction when heated. This so-called "loft" can be used for the production of lightweight components by partial consolidation. Finally, the mixed fleece is consolidated by the needling according to the invention, so that it can be handled without problems in the subsequent process steps. In a special embodiment of the invention, the needled mixed nonwoven is stretched in one direction. As a result, the reinforcing fibers in the finished part are aligned in this direction and thus bring about a particularly high mechanical level in this direction.
C. Das verfestigte Mischvlies wird im Umluftofen oder durch IR-Bestrahlung auf Temperaturen oberhalb der Erweichungstemperatur des Thermoplasten erwärmt. Vorzugsweise sollte die Temperatur 20 bis 60 °C oberhalb der Erweichungstemperatur liegen; bei Polypropylenfasern liegt sie bevorzugt zwischen 180 und 220 °C, insbesondere zwischen 190 und 210 °C.C. The solidified mixed fleece is heated in the forced air oven or by IR radiation to temperatures above the softening temperature of the thermoplastic. The temperature should preferably be 20 to 60 ° C above the softening temperature; in the case of polypropylene fibers, it is preferably between 180 and 220 ° C., in particular between 190 and 210 ° C.
D. Unmittelbar anschließend wird das erwärmte Mischvlies in einer Kaschiereinrichtung, einem Glättwerk oder einem Kalander verpreßt. Eine Kaschiereinrichtung ist eine Doppelbandpresse, die aber - im Gegensatz zu üblichen GMT-Doppelbandpressen - keine Stahlbänder aufweist, sondern Bänder aus polymer-, vorzugsweise teflonbeschichtetem Glas- oder Aramidgewebe, und wo mit wesentlich niedrigeren Drücken zwischen 1 und 10 bar gearbeitet wird. Das entstandene flächige Halbzeug weist erfindungsgemäß eine Dicke von mehr als 3,0 mm, vorzugsweise von 3,2 bis 10,0 mm auf. Die mittlere Länge der Verstärkungsfasern im Halbzeug beträgt 10 bis 60 mm, vorzugsweise sind die Fasern im Mittel weniger als 50 mm lang.D. Immediately afterwards, the heated mixed fleece is pressed in a laminating device, a smoothing unit or a calender. A laminating device is a double belt press, which - in contrast to conventional GMT double belt presses - does not have steel belts, but rather belts made of polymer, preferably Teflon-coated glass or aramid fabric, and where work is carried out with significantly lower pressures between 1 and 10 bar. The resulting flat semifinished product according to the invention has a thickness of more than 3.0 mm, preferably from 3.2 to 10.0 mm. The average length of the reinforcing fibers in the semifinished product is 10 to 60 mm, preferably the fibers are on average less than 50 mm long.
E. In einer bevorzugten Ausführungsform der Erfindung werden beim Verpressen ein- oder beidseitig Funktionsschichten an das erwärmte Mischvlies herangeführt und mitverpreßt. Dies könne Dekorschichten, dünne Faservliese, Thermoplastfolien oder Stoffbahnen sein. Grundsätzlich können die Funktionsschichten auch erst bei der Formteilherstellung aufgebracht werden. Das erfindungsgemäß hergestellte Halbzeug kann in kundenspezifische Zuschnitte vereinzelt und auf Paletten gestapelt und versandt werden. Es kann dann zu dreidimensionalen Fertigteilen thermoplastisch verformt werden. Dazu werden entsprechende Zuschnitte auf Temperaturen oberhalb der Erweichungstemperatur des Thermoplasten erwärmt und in üblichen zweiteiligen Formen verpreßt oder durch Tiefziehen verformt. Da das Halbzeug verhältnismäßig dick ist und kurze Fasern enthält, fließen diese beim Verpressen auch in feine Bereiche des Werkzeugs, so daß Fertigteile mit komplizierter Raumform und insbesondere mit filigranen Rippen hergestellt werden können. Die Fertigteile sind im Transportsektor als Automobil-, Eisenbahn- und Flugzeuginnenteile, aber auch als Karosserieteile, als großflächige Paneele sowie als Möbelteile verwendbar. E. In a preferred embodiment of the invention, functional layers are brought to the heated mixed fleece on one or both sides and pressed together. This could be decorative layers, thin non-woven fabrics, thermoplastic films or fabric panels. In principle, the functional layers can also only be applied during the production of the molded part. The semi-finished product produced according to the invention can be cut into customer-specific blanks and stacked on pallets and shipped. It can then be thermoformed into three-dimensional finished parts. For this purpose, corresponding blanks are heated to temperatures above the softening temperature of the thermoplastic and pressed in conventional two-part molds or deformed by deep drawing. Since the semi-finished product is relatively thick and contains short fibers, these also flow into fine areas of the tool during pressing, so that finished parts with a complicated spatial shape and in particular with filigree ribs can be produced. The finished parts can be used in the transport sector as automotive, railway and aircraft interior parts, but also as body parts, as large-area panels and as furniture parts.
Claims
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE10114553A DE10114553A1 (en) | 2001-03-24 | 2001-03-24 | Continuous production of glass mat reinforced thermoplastic sheet for molding automotive components involves laying down thermoplastic and reinforcing fibers to a fleece, heating and consolidating |
| DE10114553 | 2001-03-24 | ||
| PCT/EP2002/002608 WO2002076711A1 (en) | 2001-03-24 | 2002-03-09 | Method of producing a thick, thermoformable, fiber-reinforced semi-finished product |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| EP1372940A1 true EP1372940A1 (en) | 2004-01-02 |
Family
ID=7678900
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP02727385A Withdrawn EP1372940A1 (en) | 2001-03-24 | 2002-03-09 | Method of producing a thick, thermoformable, fiber-reinforced semi-finished product |
Country Status (4)
| Country | Link |
|---|---|
| US (1) | US7132025B2 (en) |
| EP (1) | EP1372940A1 (en) |
| DE (1) | DE10114553A1 (en) |
| WO (1) | WO2002076711A1 (en) |
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| USRE44893E1 (en) | 2004-03-26 | 2014-05-13 | Hanwha Azdel, Inc. | Fiber reinforced thermoplastic sheets with surface coverings |
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| US20070269644A1 (en) * | 2006-05-19 | 2007-11-22 | Azdel, Inc. | Method of increasing loft in a porous fiber reinforced thermoplastic sheet |
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- 2001-03-24 DE DE10114553A patent/DE10114553A1/en not_active Withdrawn
-
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- 2002-03-09 US US10/472,530 patent/US7132025B2/en not_active Expired - Fee Related
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Also Published As
| Publication number | Publication date |
|---|---|
| WO2002076711A1 (en) | 2002-10-03 |
| DE10114553A1 (en) | 2002-09-26 |
| US20040112501A1 (en) | 2004-06-17 |
| US7132025B2 (en) | 2006-11-07 |
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