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ES2366571T3 - Material compuesto que se puede procesar de modo termoplástico. - Google Patents

Material compuesto que se puede procesar de modo termoplástico. Download PDF

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Publication number
ES2366571T3
ES2366571T3 ES06721917T ES06721917T ES2366571T3 ES 2366571 T3 ES2366571 T3 ES 2366571T3 ES 06721917 T ES06721917 T ES 06721917T ES 06721917 T ES06721917 T ES 06721917T ES 2366571 T3 ES2366571 T3 ES 2366571T3
Authority
ES
Spain
Prior art keywords
layer
composite material
fibers
weight
thermoplastic
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.)
Active
Application number
ES06721917T
Other languages
English (en)
Inventor
Burak Baser
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.)
Mitsubishi Chemical Advanced Materials Composites AG
Original Assignee
Quadrant Plastic Composites AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Quadrant Plastic Composites AG filed Critical Quadrant Plastic Composites AG
Application granted granted Critical
Publication of ES2366571T3 publication Critical patent/ES2366571T3/es
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—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
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    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • 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
    • D04H13/00—Other non-woven fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0809—Fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2459/00—Nets, e.g. camouflage nets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
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Abstract

Material compuesto plano que se puede procesar de modo termoplástico, caracterizado porque está formado de: A. al menos una capa de tela no tejida hecha de un 10 a un 100% en peso de fibras termoplásticas, y de un 0 a un 90% en peso de fibras de refuerzo con un peso superficial de 300 a 2000 g/m2 y, B. al menos una capa de tejido hecha de fibras de refuerzo con un peso superficial de 100 a 1000 g/m2, siendo las fibras de refuerzo fibras de vidrio, y estando punzonadas entre ellas las capas A y B.

Description

Material compuesto que se puede procesar de modo termoplástico.
La invención se refiere a un material compuesto que se puede procesar de modo termoplástico que contiene al menos una capa de tela no tejida A hecha de fibras termoplásticos y una capa de tejido B hecha de fibras de vidrio.
Los plásticos termoplásticos se usan cada vez más, como consecuencia de su peso reducido, para la fabricación de piezas preformadas, en particular de piezas de automóviles. Para conferirlas una solidez y una rigidez suficiente, se unen habitualmente con fibras de refuerzo. De este modo, se fabrican, por ejemplo, semiproductos planos hechos de termoplásticos reforzados con estera de fibras de vidrio ("semiproductos GMT") por medio de la unión de esteras de vidrio textil sin fin y bandas de fundido termoplásticos, y la consolidación en una prensa de banda doble. Este modo de trabajo, sin embargo, requiere una energía necesaria elevada, ya que la masa fundida semilíquida ha de ser introducida a presión en la estera durante con una presión muy por encima de 1 bar.
Además, según este procedimiento en la práctica solo se pueden fabricar semiproductos, y con ello también piezas acabadas con un peso superficial de más de 1500 g/m^{2}.
En el documento DE-A 36 14 533 se describe un procedimiento para la fabricación de cuerpos de molde a partir de plásticos termoplásticos que contienen una inserción de refuerzo. En este caso, siguiendo la metodología de las fibras textiles se fabrica un material no tejido mixto hecho de fibras termoplásticas y fibras de refuerzo según el procedimiento de cardado o "airlay", y se compacta por medio de punzonado. Se calientan recortes de este material no tejido mixto, y se comprimen directamente para conformar cuerpos de molde. Entre dos recortes calentados se puede introducir y comprimir conjuntamente un sustrato plano, como por ejemplo un tejido de rejilla o un tejido de tela. En este caso, sin embargo, existe el peligro de que durante el manejo, es decir, durante el transporte o al introducirlo en la prensa, se deslicen las capas.
La invención se basa ahora en el objetivo de proporcionar un material compuesto que se pueda procesar de modo termoplástico, que se pueda fabricar de modo sencillo y con una necesidad de energía reducida, y que se pueda manejar sin problemas, y que pueda ser procesado para conformar un semiproducto o directamente piezas acabadas, también con un peso superficial reducido.
Este objetivo se consigue de acuerdo con la invención por medio de un material compuesto plano que se puede procesar de modo termoplástico, formado por
A.
al menos una capa de tela no tejida hecha de un 10 a un 100% en peso de fibras termoplásticas, y de un 0 a un 90% en peso de fibras de refuerzo con un peso superficial de 300 a 2000 g/m^{2} y
B.
al menos una capa de tejido hecha de fibras de refuerzo con un peso superficial de 100 a 1000 g/m^{2}, siendo las fibras de refuerzo fibras de vidrio, y estando punzonadas entre ellas las capas A y B.
\vskip1.000000\baselineskip
El documento EP-A 697 275 describe un material compuesto de fibras plano rígido a la flexión hecho de una matriz termoplástica y fibras de refuerzo, hecho de dos capas de cubierta A de tejido de fibra de vidrio, que está incorporada en una matriz termoplástica, y una capa de núcleo B a partir de la matriz termoplástica, que puede contener fibras de vidrio con orientación de fibras no direccional.
El documento EP-A 603 633 se refiere a un laminado retardante a las llamas hecho de
A.
una capa de velo de hilatura solidificado,
B.
una capa central hecha de fibras de vidrio con un peso superficial de un máximo de 30 g/m^{2}, y
C.
una lámina de metal,
estando unidas las capas entre ellas por medio de punzonado.
\vskip1.000000\baselineskip
Los laminados se han de aplicar como bandas de tejado. Contienen forzosamente una lámina metálica como capa de cubierta, que en la presente invención está descartada. Además, las piezas preformadas que se fabricaran a partir de este tipo de laminados por medio de una conformación termoplástica (en caso de que esto fuera posible), tendrían, por ejemplo una solidez y una rigidez demasiado reducida para el campo de los automóviles como consecuencia del reducido peso superficial del núcleo.
Al contrario de lo que sucede en el documento EP-A 603 633, en el material compuesto conforme a la invención no se desea una lámina de metal, y de hecho ni se requiere.
El documento EP 1 593 490 A1 y el documento DE 20 2004 007 400 U1 describen un procedimiento par ala fabricación de un semiproducto plano tomando como base un plástico termoplástico reforzado con fibra de vidrio, comprimiéndose al menos una banda A hecha de una tela no tejida con un peso superficial de 20 a 200 g/m^{2} para formar una banda B de un tejido fibroso mixto con un peso superficial de 250 a 4000 g/m^{2}, cuyas cuerdas de fibras están hechas tanto en la dirección longitudinal como en la dirección transversal de una mezcla de fibras termoplásticas y fibras de vidrio, a temperaturas por encima de la zona de reblandecimiento de los termoplásticos.
El documento WO 00/00351 describe un procedimiento para la fabricación de un cuerpo compuesto, en el que se une al menos una estera de fibras con al menos un plástico termoplástico suministrado en forma de banda, y estos materiales se unen uno con el otro bajo el efecto de presión y de temperatura elevada, insertándose entre una estera de fibras correspondiente y un plástico en forma de banda correspondiente un agente adherente.
Como fibras termoplásticas para la capa de tela no tejida A se considerar todos los plásticos termoplásticos que se puedan hilar, preferentemente polipropilenos con un MFI (230ºC, 2,16 kp) de 25 a 150 g/10 min, junto a ellos también poliamidas y poliésteres lineales, así como para determinadas finalidades de aplicación, por ejemplo en la construcción de aviones, también polisulfonos, poliétercetonas y poliéterimidas. Las fibras termoplásticas presentan por lo general una longitud media de 20 a 100 mm. La capa A está formada, preferentemente, de un 100% de fibras termoplásticas, sin embargo están indicados materiales no tejidos mixtos con hasta un 90% en peso, en particular con un 40 a 70% en peso de fibras de refuerzo. Las fibras de refuerzo preferidas son fibras de vidrio, además también están indicadas fibras naturales, fibras de aramida y fibras hechas de polímeros de fusión más elevada. Las fibras de refuerzo en la capa A presentan por lo general una longitud media de 20 a 200 mm. Para que se puedan mezclar bien con las fibras termoplásticas, han de estar como fibras individuales, no unidas. La tela no tejida de la capa A se fabrica según el procedimiento de cardado o de "airlay". En este caso se origina una tela no tejida termoplástica pura o una tela no tejida mixta con un peso superficial de 300 a 2000 g/m^{2}, preferentemente de 300 a 1000 g/m^{2}.
La capa B es preferentemente un tejido textil, por ejemplo un tejido de lino, un tejido de cuerpo o un tejido de vuelta. Las fibras de refuerzo son fibras de vidrio. Las fibras del tejido textil están preferentemente como copos de fibras con un número entre 300 y 3000 tex. Se pueden emplear rovings tanto directos como ensamblados. Los rovings ensamblados tienen la ventaja de que el número de los copos individuales puede estar entre 40 y 160 tex. La capa B tiene un peso superficial de 100 a 1000 g/m^{2}, preferentemente de 200 a 800 g/m^{2}.
La secuencia preferida de la capa es A-B-A, pudiendo tener las dos capas A también un grosor diferente. Además también son posibles, por ejemplo, las secuencias de capas A-B, y A-B-A-B-A.
Lo fundamental es que las capas A y B estén punzonadas entre sí, para que durante el transporte y durante el procesado posterior no se deslicen las capas, y al realizarse la introducción en el molde de presión solo se haya de introducir una capa única. Además, por medio del punzonado se abren los copos de fibras de la capa B, de manera que al realizarse la compresión en caliente del material compuesto se puede realizar una mejor impregnación con la masa fundida termoplástica de la capa A. El punzonado se puede llevar a cabo en telares de punzonado convencionales con agujas de fieltro.
Para la fabricación de los materiales compuestos se fabrica en primer lugar la capa de tela no tejida A según el procedimiento de cardado o de "airlay", obteniéndose una banda sin fin. La capa A, a continuación, se une y se punzona de modo continuado conjuntamente con la capa B, introduciéndose o bien entre dos capas A una capa B, o uniéndose por cada capa A y por cada capa B. Para la fabricación de la secuencia de capas A-B también se puede disponer la capa de fibras B antes del punzonado sobre el material no tejido de cardado o "airlay", y a continuación se punzona conjuntamente con éste.
Los materiales compuestos se pueden comprimir directamente para formar piezas acabadas tridimensionales en un molde a temperaturas por encima del punto de deformación del termoplástico. Sin embargo, también se puede fabricar un semiproducto, haciendo que el material compuesto se consolide de modo continuo por medio de la compresión en caliente. Esto se realiza preferentemente sobre una prensa de banda doble, si bien también se puede usar una calandria o un dispositivo de forrado. El semiproducto presenta preferentemente un grosor de 0,5 a 5,0, en particular de 1,0 a 2,0 mm, y un peso superficial de 200 a 3000, en particular de 300 a 1500 g/m^{2}. Se puede almacenar, transportar, y en caso de que sea necesario, procesar para conformar piezas acabadas. Se puede unir este semiproducto, o también directamente el material compuesto no consolidado conforme a la invención como capas de cubiertas con capas de núcleo ligeras, por ejemplo hechas de placas de material esponjado de polipropileno o placas de panal para conformar piezas de sándwich, o bien por medio de pegado o bien por medio de compresión en caliente. Además es posible unir el semiproducto con el semiproducto GMT o LFT.
Las piezas acabadas fabricadas a partir de los materiales compuestos conformes a la invención se caracterizan por una elevada solidez y rigidez, así como por medio de un peso reducido. Se usan preferentemente en el campo del automóvil, por ejemplo como refuerzo para las cavidades de las ruedas de repuesto, portones traseros, parachoques o bajos. Las piezas de sándwich son especialmente ligeras y altamente rígidas. Se pueden usar, por ejemplo, como suelo de carga en camiones. Otras posibilidades de aplicación son, por ejemplo, para artículos de deporte, en la construcción de vagones de ferrocarriles o en la construcción de aviones.

Claims (9)

1.Material compuesto plano que se puede procesar de modo termoplástico, caracterizado porque está formado de:
A.
al menos una capa de tela no tejida hecha de un 10 a un 100% en peso de fibras termoplásticas, y de un 0 a un 90% en peso de fibras de refuerzo con un peso superficial de 300 a 2000 g/m^{2} y,
B.
al menos una capa de tejido hecha de fibras de refuerzo con un peso superficial de 100 a 1000 g/m^{2}, siendo las fibras de refuerzo fibras de vidrio, y estando punzonadas entre ellas las capas A y B.
\vskip1.000000\baselineskip
2. Material compuesto de acuerdo con la reivindicación 1, caracterizado por medio de las secuencias de capas A-B-A, A-B o A-B-A-B-A.
3. Material compuesto de acuerdo con la reivindicación 1, caracterizado porque la capa de tela no tejida está hecha en un 100% de fibras termoplásticas.
4. Material compuesto de acuerdo con la reivindicación 1, caracterizado porque la capa de tela no tejida está hecha de un 30 a un 60% en peso de fibras termoplásticas y de un 70 a un 40% en peso de fibras de refuerzo.
5. Material compuesto de acuerdo con la reivindicación 1, caracterizado porque las fibras termoplásticas son fibras de polipropileno.
6. Procedimiento para la fabricación del material compuesto de acuerdo con la reivindicación 1, caracterizado porque en primer lugar se fabrica la capa de tela no tejida A según el procedimiento de cardado o de "airlay", y porque a continuación se une y se punzona conjuntamente de modo continuado una capa de tejido B con una o dos capas A.
7. Uso del material compuesto de acuerdo con la reivindicación 1 para la fabricación de piezas acabadas por medio de compresión en caliente en un molde.
8. Uso del material compuesto de acuerdo con la reivindicación 1 para la fabricación de un semiproducto plano de un grosor de 0,5 a 5,0 mm por medio de la compresión en caliente en una prensa de banda doble.
9. Uso del material compuesto de acuerdo con la reivindicación 1 como capa de cubierta para la fabricación de piezas de sándwich por medio del pegado o compresión en caliente con placas de material esponjado termoplástico o placas de panal como capa de núcleo.
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