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WO2006065538A1 - Mat a filaments continus ameliore et procede de production associe - Google Patents

Mat a filaments continus ameliore et procede de production associe Download PDF

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Publication number
WO2006065538A1
WO2006065538A1 PCT/US2005/043365 US2005043365W WO2006065538A1 WO 2006065538 A1 WO2006065538 A1 WO 2006065538A1 US 2005043365 W US2005043365 W US 2005043365W WO 2006065538 A1 WO2006065538 A1 WO 2006065538A1
Authority
WO
WIPO (PCT)
Prior art keywords
fibers
continuous filament
filament mat
fiber
predetermined
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.)
Ceased
Application number
PCT/US2005/043365
Other languages
English (en)
Inventor
Jeng Lin
Eugene V. Galloway
Frank Peel
Axel Larsen
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.)
Owens Corning Canada Inc
Owens Corning Composite Materials Canada LP
Owens Corning
Owens Corning Intellectual Capital LLC
Original Assignee
Owens Corning Canada Inc
Owens Corning Composite Materials Canada LP
Owens Corning
Owens Corning Fiberglas Technology II LLC
Owens Corning Fiberglas Corp
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 Owens Corning Canada Inc, Owens Corning Composite Materials Canada LP, Owens Corning, Owens Corning Fiberglas Technology II LLC, Owens Corning Fiberglas Corp filed Critical Owens Corning Canada Inc
Priority to CA 2589415 priority Critical patent/CA2589415A1/fr
Priority to EP20050848585 priority patent/EP1841910A1/fr
Publication of WO2006065538A1 publication Critical patent/WO2006065538A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B37/00—Manufacture or treatment of flakes, fibres, or filaments from softened glass, minerals, or slags
    • C03B37/01—Manufacture of glass fibres or filaments
    • C03B37/02—Manufacture of glass fibres or filaments by drawing or extruding, e.g. direct drawing of molten glass from nozzles; Cooling fins therefor
    • C03B37/03—Drawing means, e.g. drawing drums ; Traction or tensioning devices
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/05—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in another pattern, e.g. zig-zag, sinusoidal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/50—Glass production, e.g. reusing waste heat during processing or shaping
    • Y02P40/57—Improving the yield, e-g- reduction of reject rates
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608—Including strand or fiber material which is of specific structural definition
    • Y10T442/614—Strand or fiber material specified as having microdimensions [i.e., microfiber]
    • Y10T442/623—Microfiber is glass
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608—Including strand or fiber material which is of specific structural definition
    • Y10T442/614—Strand or fiber material specified as having microdimensions [i.e., microfiber]
    • Y10T442/626—Microfiber is synthetic polymer

Definitions

  • the present invention relates to an improved continuous filament mat (CFM) having improved weight variation along the length of the mat and a method of making such a mat.
  • CFM continuous filament mat
  • Continuous Filament Mat is a continuous reinforcement fiber, non-woven mat containing a resin compatible binder.
  • CFM is used with polyester, vinyl esters urethanes and other compatible resin systems. It includes continuous fibers randomly oriented in multiple layers with a suitable bonding resin and typically contains a silane coupling agent.
  • CFM is particularly suitable for compression molded electrical and nonelectrical laminates, as well as for use in pultrusion processes or any process in which a smooth surface is desired.
  • CFM is used in many fiberglass reinforced plastic (FRP) structural applications such as: compression molding, infusion molding, filament winding, pultrusion, reaction injection molding (RIM), resin transfer molding (RTM), and vacuum bagging. The finished molded products have high equiaxial strengths.
  • Typical products are marine railings, window frames, boat parts, high voltage transformers and corrosion resistant pipes.
  • CFM may also be combined with a woven roving to make a combination mat that has superior processability and structural properties.
  • the reinforcing filaments typically thermoplastic fibers such as glass or polymeric fibers; however, any fiber such as carbon and aramid fibers may be used.
  • the invention will be described using glass fibers as an example.
  • Compression molding is a mass production method where molding compounds and other resin glass combinations are compressed in matched metal tools located between platens in a press. Typically, pressures of 150 lbs/in 2 (105460.44 kg/m 2 ) and temperatures between 265 0 F (13O 0 C) and 34O 0 F (17O 0 C) are used to achieve cycle times of 2 - 3 minutes. Molding compounds of a thermoset resin, chopped roving, fillers and a catalyst are used in sheet molding compound (SMC). SMC is placed in the tool and covered with a layer of CFM to produce a Class A surface on parts such as automotive body panels, appliance housings and composite doors,
  • VARTM vacuum assisted resin transfer molding
  • a single-sided mold that is covered with CFM and other reinforcements and sealed with a flexible vacuum bag or film.
  • a vacuum is drawn on the space between the mold and the seal containing the reinforcements, and a thermoset resin is allowed to infiltrate the reinforcements.
  • the resin flows through the reinforcements and cures to form the finished composite.
  • Large high reinforcement content structural composite parts can be produced to make parts such as boat hulls and windmill blades.
  • Pultrusion is a continuous process for making lightweight lineal profiles such as reinforcing rods, I-beams and tubing. Pultruded parts incorporate a variety of reinforcements ranging from TYPE 30 single-end roving (available from Owens Corning of Toledo, Ohio), bulky roving, surfacing veils, CFM and woven glass fabrics. After the reinforcement is impregnated with resin, the material is pulled through a heated die that gives it a cross-sectional shape, and is then cured to create the composite profile.
  • Resin Transfer Molding is a liquid molding process where a thermosetting resin is injected into a closed mold cavity to make moderate volume semi-structural or appearance parts.
  • CFM, fabrics, multi-end preform rovings, veils, chopped strand mat and directed fiber preforms can be used in resin transfer molding as reinforcements.
  • the dry fiber reinforcement is placed in the bottom half of matching molds, the mold is closed and sealed, and then resin is slowly pumped into the mold. The resin wets through the reinforcement fibers and solidifies to form a composite part such as semi-truck parts and electrical cabinets.
  • the molding pressure is typically lower in RTM than in the compression molding process, therefore, tooling and equipment capital costs are lower than high volume compression molding, but higher than open molding processes.
  • Vacuum bagging is used to tightly consolidate composites used in windmills, aerospace parts and other applications.
  • Materials that are pre-impregnated with resin are typically laminated with vacuum bagging.
  • the components include a film or fabric, breather medium and plastic film that is applied in sequence on top of a laminate stack in an airtight mold. Air between the mold and film is extracted with a vacuum pump, resulting in a positive-pressure force. This compression forces air and excess resin from the composite laminate or components.
  • Vacuum bagging is also used in conjunction with other processes such as infusion molding and wet lay-up. CFM is formed by reciprocally depositing continuous reinforcing filaments across the width of a moving conveyor.
  • a CFM line typically includes 6 - 20 fiber draw positions from a source that randomly deposit the fibers across the width of the conveyor.
  • the fiber draw positions may include an idler wheel, a pull wheel and an oscillating finger wheel within the pull wheel. Fibers are drawn from the fiber source, around the idler wheel and over the pull wheel. The oscillating finger wheel penetrates the pull wheel to determine the angle at which the fibers are thrown from the wheel and hence, the position across the width of the conveyor. As the finger wheel oscillates, the fibers are deposited on the conveyor in a saw-tooth pattern having defined period (P). The fibers are thrown from the pull wheel faster than the fibers traverse the width of the conveyor so that the fibers form loops on the conveyor. As shown in EQ.
  • the loop formation ratio (LFR) is proportional to the pull speed (S p ) of the fibers divided by the throw length (L) and the frequency (f).
  • the period (P) is proportional to the mat line speed S m i divided by the frequency (/).
  • FIG. IA shows a graph of the relative weight verses the location in the machine direction of a CFM mat produced on a 12 draw position line at a frequency of 60 oscillations per minute (OPM), a line speed of 33 feet per minute (FPM) (10 meter per minute), and a period of 6.5 inches (16.51 centimeters).
  • OPM oscillations per minute
  • FPM line speed
  • 6.5 inches (16.51 centimeters) The peak to valley weight variation along the length of the mat ranges from 8 - 18 % by weight.
  • the fibers are deposited in random loops on the collection conveyor. With a decreasing LFR, the loops become less random and the fibers tend to lie transverse to the length of the collection conveyor. At an LFR of 3.25 a distinct transverse array becomes visible and at a LFR of less than about 2.5 the fibers are substantially transverse to the collection conveyor.
  • a high LFR is preferred in CFM because the random loop pattern increases the tensile strength of the mat.
  • a lower LFR provides a mat having a higher tensile strength in the cross-machine direction and a decreased tensile strength in the machine direction. In the prior art CFM processes, weight distribution in the mat was related to the mat line speed (S m i) and period.
  • FIG. IA shows the weight distribution in the machine direction of CFM manufactured in accordance with the prior art process.
  • the CFM line includes 12 draw positions each operating at random, the frequency (f) is 60 OPM with a line speed of 33 FPM (10 meter per minute) with a period of 6.5 in (16.51 cm).
  • the mat is built up from the 12 draw positions which are independent of one another and provide a peak to valley variation in weight that ranges from 8% to 18%. This variation in weight is increased when fiber draw positions are taken off-line due to equipment failures or for maintenance.
  • the present invention provides an improved method of forming continuous filament mat at greater through-put while maintaining or improving product quality by use of a synchronized draw process.
  • the synchronized draw process provides CFM having improved weight variation is capable of operating at increased mat line speed (S m i) and provides CFM having improved structure and tensile strength.
  • the synchronized draw process may be performed on a standard CFM line with little additional hardware and hence at low cost.
  • the additions to the CFM line include a master PLC 50 that is in communication with forming position 12 via PLC linkage 52.
  • the synchronized draw process may also include a master encoder 54 downstream from the forming position 12 to provide conveyor speed and position data to the master PLC 50 so that the forming position 12 may be individually controlled.
  • FIG. IA is a graphical representation of the weight distribution in the machine direction of CFM manufactured in accordance with a prior art process.
  • FIG. IB is a graphical representation of the weight distribution in the machine direction of CFM manufactured in accordance with one aspect of the present invention.
  • FIG. 2 is an elevation view of a forming position of the present invention including an oscillating servo drive.
  • FIG. 3 is a schematic view of the CFM line of the present invention including a master PLC in communication with forming position via PLC linkage.
  • FIG. 4A and 4B are of the profile of fibers deposited on a forming conveyor in the manufacture of a CFM in accordance with the present invention.
  • FIG. 4C is a graphical representation of the pattern of the fibers on the forming conveyor which is built up to form the CFM of the present invention.
  • FIG. 5 is a graphical representation of the standard deviation of the weight distribution in the machine direction versus the period (P) of CFM manufactured in accordance with the prior art process and in accordance with the present invention.
  • FIG. 6A is a graphical representation of the cross machine and machine direction tensile strength of CFM manufactured, at various periods, in accordance with a prior art process and in accordance with the present invention in both a 2x6 synchronized process and a 1x12 synchronized process.
  • FIG. 6B is a graphical representation of the cross machine and machine direction tensile strength of CFM manufactured, at various oscillation frequencies, in accordance with a prior art process and in accordance with the present invention in both a 2x6 synchronized process and a 1x12 synchronized process.
  • the improved continuous filament mat of the present invention as shown and described herein provides a lower weight variation and is capable of increased and less expensive manufacture by increasing the through-put of a CFM line.
  • the improved product quality and line speed is achieved by use of a synchronized draw process.
  • the synchronized draw process provides CFM having improved filament structure and tensile strength.
  • the synchronized draw process may be performed on a standard CFM line with little additional hardware and hence at low cost.
  • the additions to the CFM line include a master PLC 50 that is in communication with forming position 12 via PLC linkage 52.
  • the synchronized draw process may include a master encoder 54 downstream from the forming position 12 to provide conveyor speed and position data to the master PLC 50 so that the forming position 12 may be individually controlled.
  • the fibers used in the manufacture of the CFM may be any type of glass fibers, such as A-type glass fibers, C-type glass fibers, E-type glass fibers, S-type glass fibers, ECR-type glass fibers (such as., Advantex ® glass fibers commercially available from Owens Corning), or modifications thereof.
  • any suitable fibers such as, but not limited to, mineral fibers, carbon fibers, basalt fibers, polymer fibers, nylon fibers, polyester fibers, polyamide fibers, aramid fibers, PVC fibers, PVAC fibers, melamine fibers, acrylic fibers, visil fibers, natural fibers, staple fibers, chopped fibers and mixtures thereof may be used.
  • Glass fibers may be formed by attenuating streams of a molten glass material from a bushing or orifice to form glass fibers.
  • the molten glass may be attenuated rollers which pull the fibers before they are fed to the forming position 12.
  • An aqueous sizing composition may be applied to the fibers after they are drawn from the bushing to protect the fibers from breakage during subsequent processing, to retard interfilament abrasion, and to ensure the integrity of the strands of glass fibers, that is, the interconnection of the glass filaments that form the strand.
  • Sizing compositions are well-known in the art, and typically include a film forming polymeric or resinous component, a coupling agent, and a lubricant.
  • the film forming component of the size composition is desirably selected to be compatible with the matrix resin or resins in which the glass fibers are to be embedded.
  • the sizing composition used in the present invention is not particularly limited, and may be any sizing known to those of ordinary skill in the art or developed hereafter.
  • the binder composition may optionally contain conventional additives such as dyes, oils, fillers, thermal stabilizers, emulsifiers, anti-foaming agents, anti-oxidants, organosilanes, colorants, UV stabilizers, and/or other conventional additives.
  • additives include coupling agents (for example, silane, aminosilane, and the like), dust suppression agents, lubricants, wetting agents, surfactants, antistatic agents, and/or water repellent agents.
  • FIG. IB shows the weight (on a relative scale) of a CFM manufactured in accordance with one aspect of the present invention.
  • FIG. IB shows the weight of a CFM manufactured using 6 position synchronization where the frequency is 30 OPM and the line speed is 33 FPM (10 meter per minute).
  • the lower curves represent the weight from each fiber forming position.
  • the curves have a predefined interval and the sum of the individual curves provides a substantially stable weight across the mat.
  • the CFM shown in FIG. IB has a period of 333 mm and a peak to valley variation of 1.6%. Comparing FIG. IA to FIG. IB it can be seen that the CFM of the present invention provides a predetermined fiber lay down pattern in a pattern having a predetermined interval.
  • FIG. IB shows the weight of a CFM manufactured using 6 position synchronization where the frequency is 30 OPM and the line speed is 33 FPM (10 meter per minute).
  • the lower curves represent the weight from each fiber forming position.
  • IB shows the use of 6 fiber groups laid down at a predetermined interval, in this case the interval is equal among all plies, but is possible to manufacture a mat having a 1 x 5 synchronization and a 1 x 6 synchronization pattern where the periods of the two patterns is unequal.
  • the forming position 12 includes a fiber draw position 30 from which fibers 32 are drawn.
  • the fibers 32 are drawn around idler wheel 28 and around fiber pull wheel 14.
  • the fiber pull wheel 14 is mounted on drive shaft 16 which is connected to oscillating servo drive 22 and suspended from support structure 26.
  • the forming position 12 includes a shield 24.
  • the oscillating servo drive 22 is linked to master PLC 50 via PLC linkage 52.
  • the oscillating servo drive 22 also controls oscillator 20 which drives oscillating finger wheel 18 across a portion of the circumference of fiber pull wheel 14 to control the angle at which the fibers 32 leaves the fiber pull wheel 14 and hence the position of fibers 32 on forming conveyor 10.
  • FIG. 3 is a system overview showing one embodiment of the synchronized continuous filament mat line according to the present invention.
  • the CFM line includes a series of N forming positions 12. Typically N may range from 2-20 forming positions 12 or more. Preferably, the CFM line includes between 12 and 20 forming positions 12.
  • Each forming position 12 lays fibers 32 on forming conveyor 10 in a V-shaped pattern as controlled by oscillating servo drive 22.
  • the oscillating servo drive 22 is linked to the master PLC 50 via PLC linkage 52.
  • the PLC linkage 52 may be an electrical communications cable, an optical link, a radio frequency connection or any other suitable data transfer device.
  • Each forming position 12 is also linked to master encoder 54 via encoder linkage 56.
  • the encoder linkage 56 may be an electrical communications cable, an optical link, a radio frequency connection or any other suitable data transfer device.
  • the master encoder 54 may continuously monitor the conveyor speed and position and provide feedback to the master PLC 50 to control the oscillation of the fiber pull wheel 14.
  • the master PLC 50 is programmed with algorithms that enable the deposition of fibers to be altered in the event that a forming position 12 goes off-line so that production of the CFM 60 may continue with little or no density variation.
  • the master PLC 50 is typically linked to a Human Machine Interface 5OA such as a CRT or video touch screen to provide monitoring, control or override of the master PLC 50.
  • a Human Machine Interface 5OA such as a CRT or video touch screen
  • FIGs. 4A-4B show the profile of the mean fiber position of fibers 32 from forming position 12 as deposited on the forming conveyor 10.
  • the mean fiber position shown as a line equal to the center position of the loops of fibers 32 formed on the forming conveyor 10.
  • the profile is controlled by the speed of the forming conveyor 10 as well as the movement of the oscillating finger wheel 18.
  • the x-axis is along the length of the forming conveyor 10 and the y-axis is across the length of the conveyor.
  • the profile definition variables are typically defined by the period, frequency and interval.
  • a cycle is one complete motion of the oscillator back and forth across the width of the line.
  • the period is the distance in millimeters along the x-axis of one complete cycle.
  • the frequency is number of cycles completed in one minute and is expressed in oscillations per minute (OPM).
  • OPM oscillations per minute
  • the lay-down pattern from the forming positions 12 Prior to formation of a CFM 60, the lay-down pattern from the forming positions 12 are typically calibrated. Calibration determines the mean fiber position of each position 12 and allows for the determination of the profile definition variables. Two potential calibration techniques include forming position calibration and fiber position calibration.
  • Forming position calibration presupposes careful measurement and calibration between each of the banks of forming positions 12 and between each fiber draw position 12 in the individual banks.
  • each forming position 12 In fiber position calibration, the distance and skew angle of each forming position 12 is not measured but rather the fiber strands 32 are projected onto the forming conveyor and the pull wheel is adjusted, either mechanically or electronically through the master PLC, so that an interval of a known value is achieved. Typically, the interval is set to zero during calibration so that an operator can easily observe the fiber strand 32 position and control the mean fiber position of each fiber draw position 12 so that the mean fiber position from each fiber draw position 12 is overtop the mean fiber position on the first fiber raw position 12 in the bank. The opposed banks are then calibrated each to the other, typically so that they are 180° out of phase.
  • the master PLC 50 is programmed to control the profile definition variables so that a CFM 60 having predetermined properties is produced.
  • the master PLC 50 linked to the oscillating servo-drive 22 controls the oscillator 20 to drive oscillating finger wheel 18 across a portion of the circumference of fiber pull wheel 14.
  • the position of finger wheel 18 controls the angle at which the fibers 32 leaves the fiber pull wheel 14 and hence the position of the fiber strand 32 on the forming conveyor 10.
  • the master PLC 50 controls the speed and relative positions of finger wheel 18 to control the interval between fiber strands 32.
  • a the master PLC is preprogrammed with a variety of product specific algorithms for the profile definition variables by controlling the speed of forming conveyor 10, speed of the pull wheel 14, frequency (/), the position of the finger wheels 20 and a time offset between servo-drives 22.
  • the interval between two forming positions 12 is shown in FIG. 4B.
  • the interval is the distance in millimeters between the mean fiber positions of one forming position 12 with respect to another forming position 12.
  • the interval is defined by the distance between the mean fiber positions of adjacent forming positions 12 in a 1-3-5-7-9-
  • fibers 32 from forming positions 1, 3, and 5 may be deposited with an interval greater than the desired interval of the finished product and fibers 32 from positions 7, 9 and 11 may be deposited over the top so that fibers 32 from position 7 lie between the fibers 32 of positions 1 and 3; fibers 32 from position 9 lie between the fibers 32 of positions 3 and 5; and fibers 32 from position 11 lie between the fibers 32 of positions 5 and 1.
  • the interval between fibers 32 would lie in a 1-7-3-9-5-11 pattern
  • FIG. 4C shows a CFM profile of a four oscillator synchronization pattern including first fiber position 62, second fiber position 64, third fiber position 66, and fourth fiber position 68.
  • the density variation of the CFM 60 is reduced.
  • the number N of forming positions 12 increases, it is possible to control the interval of the forming positions 12 to form a substantially uniform density CFM 60. It is possible to substantially increase the period to allow for faster speeds forming conveyor 10 and increased machine output while controlling the weight variation and the interval so that the sum of the intervals is equal to the period.
  • a multi-ply CFM 60 being built up from multiple patterns, such as that shown in FIG. 4C, including first fiber position 62, second fiber position 64, third fiber position 66, and fourth fiber position 68, so that the each ply includes four fiber strands 32.
  • a CFM mat 60 having 4 plies of 3 forming positions 12 or in a CFM line having 20 forming positions 12 a CFM mat 60 having 4 plies of 5 forming positions 12 may be formed.
  • the mean fiber position of the first fiber position 62 of each succeeding ply may be deposited substantially on top of the mean fiber position of the first fiber position 62 of the preceding ply or, optimally, it may be spaced apart from the mean fiber position of the first fiber position 62 of the preceding ply.
  • the fiber draw positions 12 are numbered consecutively down the line, that is, in a twelve position line, position one at the east end of the line while position twelve is at the west end.
  • the positions are typically not centered over the forming conveyor 10 but the even positions (2-4-6-8-10-12) form a bank that is offset to the north side and odd positions (1-3-5-7-9-11) form a bank that is offset to the south side (the ordinal directions are used for the purposes of example only).
  • the line operator may select a desired preprogrammed pattern or establish a unique pattern for a desired CFM configuration through Human Machine Interface 5OA. Based on the number of on-line forming positions 12, the master PLC 50 then calculate the intervals to lay down the fibers 32 in the desired pattern. The master PLC 50 may then monitor the output of each forming position 12 and, in the event that a forming position 12 goes offline due to a fibers 32 breakout, a mechanical failure or for scheduled maintenance, the master PLC 50 can control the cycle, period, frequency, interval as well as the speed of forming conveyor 10 and the pattern of the forming positions 12 to minimize or eliminate any flaws in the CFM mat 60 and to maintain the product base weight.
  • the algorithms used to control the lay down pattern may include fixed period, fixed frequency or any other suitable algorithm to provide suitable lay down pattern.
  • a PLC 50 using a fixed period algorithm will decrease the frequency (f), reduce the mat line speed (S m i), maintain a fixed oscillation period (P), and increase the interval of the forming position bank to account for the loss of one or more forming position 12.
  • a PLC 50 using a fixed frequency algorithm will decrease the period (P) and the mat line speed (S m i) in order to maintain a fixed frequency and maintain the interval of the forming position bank to account for the decreased period (P) due to the loss of one or more forming positions 12.
  • FIG. 5 shows a plot of pooled standard deviation (PSD) of machine direction (MD) weight variation versus period in millimeters.
  • PSD pooled standard deviation
  • MD machine direction
  • FIG. 5 shows the PSD MD weight variation of a non-synchronized mat of the prior art, the PSD MD weight variation of a synchronized mat of the present invention formed on a twelve position line where the banks are separately synchronized but are not synchronized to one another, and the PSD MD weight variation of a synchronized mat of the present invention formed on a twelve position line where the banks are separately synchronized and are synchronized to one another.
  • FIG. 5 also shows that it is possible to manufacture CFM within a wide manufacturing process window based upon fiber generation capacity, the number of forming positions 12, line speed, period (P), and frequency.
  • a synchronized CFM may be formed having reduced weight variation and at increased line speeds. Further, through control of the oscillation rate, it is possible to control the loop formation ratio (LFR) and hence the CM and MD tensile strength of the CFM. Specifically, it is possible to control the CM/MD tensile strength ratio. It is desirable to have a CFM with an increased MD tensile strength in products such as pultrusion. In other products, such as compression molding, infusion molding and resin transfer molding, equiaxial strength may be desired. As shown in FIG. 6A and 6B, it is possible to control the CM/MD tensile strength ratio and therefore to tailor the CFM to the desired properties.
  • Table 1 shows theoretically determined properties of four continuous filament mats (examples 1-4). Examples 1 and 2 are based on the CFM technology of the prior art. Examples 3 and 4 are based on the CFM technology of the present invention. As seen in Table 1, Ex. 3 has the same basis weight and mat line speed as Ex. 1, but with significantly lower frequency and peak to valley weight variation and at a higher loop formation ratio (LFR) and period. Similarly, Ex. 4 has the same basis weight and mat line speed as Ex. 2, but with significantly lower frequency and peak to valley weight variation and at a higher loop formation ratio (LFR) and period.
  • LFR loop formation ratio
  • Tables 2A-2C show the data used to create FIG. 5 and shows the pooled Standard Deviation of the MD weight variation of CFM having a density of 28.4 g/ft 2 .
  • Table 2A shows that the weight variation for a non-synchronized CFM increased dramatically for a period above 165 mm. The weight variation is typically unacceptable to the composites industry and limits the overall throughput of a CFM.
  • Table 2B shows that the weight variation for a 2x6 synchronized CFM was initially lower than that of the non- synchronized CFM and increased at a lower rate with increased period.
  • Table 2C shows that the weight variation for a 1x12 synchronized CFM was initially lower than that of both the non-synchronized and the 2x6 synchronized CFM and increased at a substantially lower rate with increased period.
  • FIG. 5 shows that the PSD weight variation is lower at a period of 350 mm than at 160 mm and 165 mm for the 2x6 synchronized and the unsynchronized CFM. The higher period and lower PSD weight variation allows a CFM line to run at a substantially increased throughput without the cost of additional forming positions.
  • the data from FIG. 6 A and 6B is shown in Table 3.
  • the oscillation rate is related to the ratio of the cross machine tensile strength to the machine direction tensile strength (CM/MD).
  • the examples were produced and tested for tensile strength in both the machine direction (MD) and in the cross-machine direction (CM).
  • CM machine direction tensile strength
  • Table 3 Ex. 30 has improved MD tensile strength over Ex. 31-33, as expected, due to the decreased frequency and the increased LFR.
  • the MD tensile strength is 81% of the CM tensile strength which is very desirable in certain composite applications.
  • MD/CD tensile strength ratio

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  • General Life Sciences & Earth Sciences (AREA)
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Abstract

L'invention concerne un procédé amélioré de formation d'un mat à filaments continus (CFM) à un rendement supérieur tout en maintenant ou en améliorant la qualité du produit au moyen d'un processus d'étirage synchronisé. Le processus d'étirage synchronisé permet d'obtenir un CFM présentant une variation de poids, une structure et une résistance à la traction améliorées et peut fonctionner à une vitesse de production de mats élevée. Le CFM obtenu peut présenter une densité de mat, une variation de densité dans le sens machine, une variation de densité dans le sens travers, une résistance à la traction dans le sens machine et une résistance à la traction dans le sens travers commandées par commande de la période, de la fréquence et de l'intervalle des brins de fibres déposés. La technologie de synchronisation de l'invention permet de commander le rapport de résistance à la traction (sens machine/sens travers) afin de répondre à des besoins spécifiques d'un utilisateur par ajustement du rapport LFR, de la fréquence, de la période, et de la vitesse de production. Le procédé de l'invention permet d'améliorer le rendement d'un équipement de production de CFM spécialisé et coûteux sans dépenses importantes supplémentaires.
PCT/US2005/043365 2004-12-16 2005-12-01 Mat a filaments continus ameliore et procede de production associe Ceased WO2006065538A1 (fr)

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EP20050848585 EP1841910A1 (fr) 2004-12-16 2005-12-01 Mat a filaments continus ameliore et procede de production associe

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US11/014,387 US20060135017A1 (en) 2004-12-16 2004-12-16 Continuous filament mat and method of making

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NL1037958C2 (en) * 2010-05-12 2011-11-15 Willem Frans Mast A method and a system for producing a mat of fibrous material.

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US20110070419A1 (en) * 2009-09-18 2011-03-24 Sang-Hoon Lim Nonwoven fire barrier with enhanced char performance
CN113862901A (zh) * 2021-10-28 2021-12-31 重庆智笃新材料科技有限公司 一种纤维毡及其制作工艺

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WO2011142658A3 (fr) * 2010-05-12 2011-12-29 Willem Frans Van Der Mast Procédé et système pour produire un mat de matière fibreuse

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