CN113365801B - 制造具有改进的压缩强度的片状复合部件的方法 - Google Patents

制造具有改进的压缩强度的片状复合部件的方法 Download PDF

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CN113365801B
CN113365801B CN201980077858.9A CN201980077858A CN113365801B CN 113365801 B CN113365801 B CN 113365801B CN 201980077858 A CN201980077858 A CN 201980077858A CN 113365801 B CN113365801 B CN 113365801B
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core layer
fibers
oriented
arrangement
raised
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CN113365801A (zh
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B.巴瑟
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Mitsubishi Chemical Advanced Materials Co ltd
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Mitsubishi Chemical Advanced Materials Co ltd
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Abstract

制造片状复合部件的方法，其包括以下工艺步骤：a)提供基本上平面的布置体(A，B，A')，其包括夹在一对表皮层(A，A')之间的芯层(B)，芯层的第一面与所述表皮层中的第一个(A)相邻并且基本上平行，并且芯层的第二面与所述表皮层中的另一个(A')相邻并且基本上平行，表皮层(A，A')各自包含表皮热塑性材料和任选地增强纤维，芯层(B)包含由起绒热塑性纤维和增强纤维制成的起绒材料；b)加热并且加压夹层布置体(A，B，A')，然后冷却，从而获得复合部件。为了改进复合部件的压缩强度，芯层(B)是具有主要在垂直于第一和第二面的取向方向(Z)上取向的增强纤维的Z‑取向芯层。提供所述Z‑取向芯层的方法包括以不同运输速度的多重折叠、纵向压缩和针刺。

Description

制造具有改进的压缩强度的片状复合部件的方法
技术领域
本发明涉及一种制造具有改进的压缩强度的片状复合部件的新颖方法。
背景技术
由纤维增强的热塑性材料制造的复合部件已在许多技术领域中得到广泛使用。
例如，WO 2015/117799A1公开了一种包含泡沫芯的复合部件，其具有第一和第二表皮层，所述第一和第二表皮层与该泡沫芯分别在其第一表面和第二表面上结合。类似地，WO 2006/133586公开了一种抗挠刚性复合片材，其包括：由玻璃含量为20至60重量％并且空隙含量小于5体积％的玻璃纤维增强的聚丙烯制成的厚度为0.5至5mm的一个或两个表皮层，和由玻璃含量为35至80重量％并且空隙含量为20至80体积％的玻璃纤维增强的聚丙烯制成的厚度为2至40mm的芯层。如在WO 2006/105682 A1中大量描述的，这样的多孔芯片材可通过聚丙烯纤维和玻璃纤维的干混、共混的非织造材料的针刺(needling)以及热压来形成。
一个长期的挑战在于寻求在保持重量尽可能小的同时优化机械性质。在许多情况下，通过相对厚的芯层进行所述制造过程将会是期望的。芯层厚度的简单按比例放大会导致如下缺点：最初软的芯层当在热压步骤中施加表皮层时不提供足够的压缩强度。因此，如下将是期望：提供一种涉及具有改进的压缩强度的芯层的改进的制造方法。
发明内容
根据本发明，提供了一种制造片状复合部件的方法，其包括以下工艺步骤：
a)提供基本上平面的布置体(A，B，A')，其包括夹在一对表皮层(A，A')之间的芯层(B)，芯层的第一面与所述表皮层中的第一个(A)相邻并且基本上平行，并且芯层的第二面与所述表皮层中的另一个(A')相邻并且基本上平行，表皮层(A，A')各自包含表皮热塑性材料和任选地增强纤维，芯层(B)包含由起绒(fleece，绒布，绒毛)热塑性纤维和增强纤维制成的起绒材料，
b)将夹层布置体(A，B，A')加热和加压，随后冷却，从而获得复合部件。
术语“表皮层”应以其最宽泛的含义理解为是指附接至内部或芯结构的表面层。上表皮层和下表皮层可具有或不具有相等的厚度。表皮层中的每个都包含热塑性材料，为了清楚起见在此称为“表皮热塑性材料”。此外，每个表皮层任选地包含增强纤维。
芯层通过由热塑性纤维和增强纤维制成的起绒材料形成。为了清楚起见，构成热塑性纤维的材料在本文被称为“起绒热塑性材料”。
作为构成芯层的一种材料的纤维增强的热塑性起绒材料被广泛用在许多技术领域中，特别地用于生产具有有利结构性质的轻型部件。它们典型地用完善的梳理(carding)或气流成网(air-laying)技术生产，并且基本上形成为片材。作为生产过程的结果，这样的起绒材料的纤维大体上在片材平面内(即在可定义为“X-Y-平面”的平面内)取向。虽然所知晓的是，在垂直于片材平面的方向上针刺起绒材料使在Z-方向上取向的增强纤维的量略有增加，但是再取向效果相对较小，因此X-Y-取向仍然占主导。
然而，根据本发明，芯层B是具有主要在垂直于第一和第二面的取向方向Z上取向的增强纤维的Z-取向芯层。以这种方式，获得了显着改进的压缩强度。
应强调，上述特征“主要的(占主导或优势的，predominant)Z-取向”(即垂直于由所述第一和第二面限定的X-Y参考平面)并不排除第二(次要)方向的优先取向(即一个特定的面内方向，例如Y)。但是，毫无疑问地，这暗示与各向同性的情况相比在Z-方向上的主要性。
根据一个有利的实施方案，所述Z-取向芯层(B)通过如下而提供：将所述起绒材料的片材多重折叠成相互平行并且相邻的片材部分通过第一或第二折叠边缘成对地连接的连续折叠的布置体(rangement)从而产生所述Z-取向芯层，所述第一或第二折叠边缘分别沿着连续折叠的布置体的第一面或第二面定位，所述Z-取向芯层具有暴露的第一和第二面以将表面层(A)和(A')施加到其从而形成用于后续工艺步骤b)的所述夹层布置体(A，B，A')。
根据一个实施方案，所述多重折叠是用适当的机械折叠装置来进行的，所述机械折叠装置例如被配置为夹具、保持器、止动表面(stopping surface，停止表面)等。
根据另一个实施方案，所述多重折叠作为如下的连续过程进行：其中所述起绒材料的片材沿着加工方向(X)以第一速度(v1)供应，并且随后将其减慢至比所述第一速度(v1)慢的第二速度(v2)，从而导致所述多重折叠。
在某些实施方案中，芯层通过提供单一的连续折叠的布置体而构成。在其他实施方案中，芯层(B)包含堆叠的多个所述起绒材料的连续折叠的布置体。例如，芯层可包含两个或更多个在彼此上面堆叠的相同的连续折叠的布置体，即形成双层或多层。这包括其中两个堆叠的连续折叠的布置体基本上“同相的(in phase)”(即，每个连续折叠的布置体的折叠边缘在相同的纵向位置处)的布置体。替代地，两个堆叠的连续折叠的布置体可为“异相的(out of phase)”，从而移位并因此最小化折叠边缘的突出效果。除了至少一种连续折叠的布置体之外，还可布置至少一个未折叠的起绒材料层。这允许改进复合部件的表面品质，其包括在压缩步骤中形成的焊接线的封闭性。
根据另一个实施方案，Z-取向芯层(B)通过以下提供：将起绒材料填充到具有固定的上壁、下壁、侧壁和端壁的压缩单元中，通过端壁之间的距离减小来施加纵向机械压缩步骤，随后移除上壁和下壁，由此产生侧向受限和纵向压缩的起绒材料，从而形成所述Z-取向芯层，所述Z-取向芯层具有暴露的第一和第二面用以向其施加表面层(A)和(A')以形成用于后续工艺步骤b)的所述夹层布置体(A，B，A')。
根据又一个实施方案，Z-取向芯层(B)通过使所述起绒材料通过加工单元从而产生所述Z取向芯层的连续片材而连续地提供，所述加工单元依次地沿着加工方向(X)包括压缩站、膨胀站和针刺站，所述压缩站包含以第一距离(d1)间隔开并且以第一速度(v1)运行的第一辊对，所述膨胀站包含以第二距离(d2)间隔开并且以第二速度(v2)运行第二辊对，其中d2>d1并且v2<v1，并且所述针刺站包括多个垂直于加工方向(X)往复运动的针刺元件，所述Z取向芯层具有暴露的第一和第二面用以向其施加表面层(A)和(A')以形成用于后续工艺步骤b)的所述夹层布置体(A，B，A')。第二距离d2实质上大于、典型地至少以5倍，优选地至少以10倍大于第一距离d1。第二速度v2实质上小于、典型地以与前面提到的距离倍数相对应的倍数小于第一速度v1；。
如在纤维增强的热塑性材料的领域中所知晓的，增强纤维可选自各种各样的，其包括但不限于玻璃纤维、碳纤维、芳族聚酰胺纤维、玄武岩纤维和天然纤维。替代地，增强纤维可由高熔点热塑性材料，即在热压步骤的加工温度下不熔化的材料，制成。根据一个有利的实施方案，增强纤维是玻璃纤维。
起绒热塑性材料和表皮热塑性材料可独立地选自各种已知的聚合物，例如聚丙烯(PP)、聚醚酰亚胺(PEI)、聚砜(PSU)、聚醚砜(PES)、聚苯砜(PPSU)、聚邻苯二甲酰胺(PPA)、聚苯醚(PPO)、聚醚醚酮(PEEK)聚苯硫醚(PPS)、聚酰胺(PA)、聚芳基醚酮(PAEK)、聚醚酮酮(PEKK)和聚碳酸酯(PC)。有利地，起绒热塑性材料和表皮热塑性材料是相同或相互相容的热塑性聚合物。
在许多有利的实施方案中，增强纤维是碳纤维，并且起绒热塑性材料和表皮热塑性材料是PP，优选为熔体流动指数MFI(230℃，2.16kg)为5至500、优选为10至200g/10min的聚丙烯。
在某些实施方案中，至少一种表皮层(A，A')包含增强片材，所述增强片材由织造织物、非卷曲织物或单向纤维布置体组成。
取决于应用，在工艺步骤b)之前提供的芯层(B)的面积重量为50至10'000g/m2。
附图说明
通过参考以下结合附图对本发明的各种实施方案的描述，本发明的上述和其他特征和目的以及实现它们的方式将变得更加明显，并且将更好地理解本发明本身，在所述附图中：
图1以透视图示出根据现有技术的待加工的布置体；
图2也以透视图示出图1的布置体的芯层；
图3作为垂直于片材平面的垂直截面(纵断面)示出根据第一实施方案处理的具有折叠的布置体；
图4作为垂直于片材平面的垂直截面示出根据第二实施方案处理的具有折叠的布置体；
图5作为垂直于片材平面的垂直截面示出根据第三实施方案处理的具有折叠的布置体；
图6作为垂直于片材平面的垂直截面示出根据第四实施方案处理的具有折叠的布置体；
图7至10作为垂直于纸张平面的垂直截面示出根据第五实施方案的具有纵向压缩的各种工艺步骤；和
图11作为垂直于片材平面的垂直截面示出根据第六实施方案的方法的具有针刺的布置体。
具体实施方式
将理解，附图不一定按比例绘制。在某些情况下，相对尺寸是明显变形的，以便于可视化。在各个附图中，相同或相应的特征通常用相同的符号表示。
图1至3中示出了根据现有技术的制造片状复合部件的方法。如图1中大体描绘的，该方法开始于提供基本上平面的布置体(A，B，A')，其包括夹在一对表皮层(即上表皮层A和下表皮层A')之间的芯层B。在所示的实例中，芯层B由在彼此上面堆叠的两个单独层B1和B2构成。
芯层B的第一面与上表皮层A相邻并且基本上平行，而芯层的第二面与下表皮层A'相邻并且基本上平行。
两个表皮层A、A'各自包含表皮热塑性材料和任选地增强纤维。芯层B(即单独层B1和B2中的每个)包含由起绒热塑性纤维制成的起绒材料F，并且进一步包含增强纤维R1、R2等。
如图2所示，在每个芯层中的增强纤维R1、R2等的取向主要在层平面内，即在由方向矢量X和Y所跨越(延伸)的平面内。更准确地，增强纤维以这样的方式取向：其纵向纤维方向在面外方向Z上不具有实质性的分量。应指出，这也适用于弯曲的纤维，在该情况下必须考虑沿纤维的任何点处的局部纤维方向。
现在在图3中说明本发明的基本构思。与图1和图2所示的情况形成对比，现在大量增强纤维R1、R2等具有垂直于芯层的面的方向分量，即沿平面外方向Z。
在图3所示的实例中，这通过具有经由将起绒材料的片材2多重折叠成如下的连续折叠的布置体构成的芯层(B)而实现：相互平行并且相邻的片材部分2a、2b、2c等通过分别沿着连续折叠的布置体的第一面8或第二面10定位的第一折叠边缘4或第二折叠边缘6成对地连接。更具体地，在图3的实例中，片材部分2a和2b通过第一折叠边缘4连接，而片材部分2b和2c通过第二折叠边缘6连接。这产生具有然后将表面层A和A'施加到其以形成夹层布置体A，B，A'的暴露的第一和第二面8、10的Z-取向芯层。
然后，可使如此获得的夹层布置体A，B，A'经历加热和加压步骤，随后冷却，从而获得具有优异的压缩强度性质的片状复合部件。
在图4至6中示出使用折叠的起绒片材材料的基于相同原理的其他实施方案。
在图4的实例中，芯层B包含一个连续折叠的布置体12a和一对相同起绒材料的未折叠的层12b和12c。在该特定实例中，折叠的层12a位于未折叠的层12b和12c之间。
在图5的实例中，芯层B包含两个连续折叠的布置体12d和12e，其在彼此上面堆叠并且形成位于上表皮层A和下表皮层A'之间的双层。在此处所示的布置体中，两个堆叠的连续折叠的层12d和12e是基本上“异相的”，从而移位并因此最小化折叠边缘的突出效果。
在图6的实例中，芯层B包含三重堆叠体，其包含两个连续折叠的布置体12d和12e以及定位于其间的未折叠的层12f。
在某些实施方案中，多重折叠的层作为如下的连续过程进行：其中所述起绒材料的片材沿着加工方向(X)以第一速度(v1)供应，并且随后减慢至比所述第一速度(v1)慢的第二速度(v2)，从而导致所述多重折叠。
在图7至10中示出的第五实施方案中使用提供Z-取向芯层的一种不同方法。此处，所需的Z-取向芯层B通过将包含起绒热塑性纤维和增强纤维的起绒材料102填充到具有固定的上壁106、下壁108、侧壁(未示出)和端壁110和112的压缩单元104中而形成。最初，在图7所示的情况下，增强纤维的取向是基本上各向同性的。通过在这种情况下施加经由减小端壁之间的距离而实现的纵向机械压缩步骤，产生如图8所示的侧向受限和纵向压缩的起绒材料102a。在这种情况下，增强纤维优先地在垂直于压缩方向X上取向。上壁和下壁的移除提供具有暴露的第一(上)面114和第二(下)面116的Z-取向芯层。之后在其上施加上表面层A和下表面A'以形成如图9所示的夹层布置体A，B，A'。最后，如图10所示，使夹层布置体A，B，A'经历用适当的工具118的加热和加压步骤，随后冷却，从而获得具有优异的压缩强度性质的片状复合部件。
在第六实施方案中使用提供Z-取向芯层的又一种方法，其在图11中示出。在这种情况下，所需的Z取向芯层B通过使包含起绒热塑性纤维和增强纤维R的起绒材料202通过加工单元204而连续地产生。加工单元204沿着加工方向X顺序地包括压缩站206、膨胀站208和针刺站210。更具体地，压缩站206包含以第一距离d1间隔开并且以第一速度v1运行的第一辊对212。后续的膨胀站208包含以第二距离d2间隔开的第二辊对214，所述第二距离d2实质上大于第一距离1。第二辊对以实质上小于第一速度v1的第二速度v2运行。如图11所示，起绒材料遵循加工单元的渐扩的(diverging)横截面轮廓，有效地导致膨胀。后一种现象导致在起绒材料中包含的增强纤维R的再取向，以优先地在垂直于加工方向X上取向。为了保持所得的Z-取向，材料通过针刺站210，所述针刺站210包含垂直于加工方向X往复运动的多个针刺元件216。如此获得的Z-取向芯层具有暴露的第一(上)面218和第二(下)面220。
因为所述芯层作为基本上无端(环状)的材料制造，所以接下来施加上表面层A和下表面A'以形成用于后续的加热和加压、随后冷却的夹层布置体A，B，A'可以连续过程进行。替代地，所述Z-取向芯材料可被切成段并且通过施加相应的表面层材料段而加工。

Claims (9)

1.制造片状复合部件的方法，其包括以下工艺步骤：
a)提供基本上平面的布置体(A，B，A')，其包括夹在一对表皮层(A，A')之间的芯层(B)，所述芯层的第一面与所述表皮层中的第一个(A)相邻并且基本上平行，并且所述芯层的第二面与所述表皮层中的另一个(A')相邻并且基本上平行，所述表皮层(A，A')各自包含表皮热塑性材料和任选的增强纤维，所述芯层(B)包含由起绒热塑性纤维和增强纤维制成的起绒材料，
b)将夹层布置体(A，B，A')加热和加压、随后冷却，从而获得复合部件；所述方法特征在于
所述芯层(B)是具有主要在垂直于第一和第二面的取向方向Z上取向的增强纤维的Z-取向芯层，
其中所述Z-取向芯层(B)通过如下而提供：将所述起绒材料填充到具有固定的上壁、下壁、侧壁和端壁的压缩单元中，通过所述端壁之间的距离减小来施加纵向机械压缩步骤，随后移除上壁和下壁，由此产生侧向受限和纵向压缩的起绒材料，从而形成所述Z-取向芯层，所述Z-取向芯层具有暴露的第一和第二面以将表面层(A)和(A')施加到其以形成用于后续工艺步骤b)的所述夹层布置体(A，B，A')，或
其中所述Z-取向芯层(B)通过使所述起绒材料通过加工单元从而产生所述Z取向芯层的连续片材而连续地提供，所述加工单元沿着加工方向(X)顺序地包括压缩站、膨胀站和针刺站，所述压缩站包含以第一距离d1间隔开并且以第一速度v1运行的第一辊对，所述膨胀站包含以第二距离d2间隔开并且以第二速度v2运行第二辊对，其中d2>d1并且v2<v1，并且所述针刺站包括多个垂直于加工方向(X)往复运动的针刺元件，所述Z取向芯层具有暴露的第一和第二面以将表面层(A)和(A')施加到其以形成用于后续工艺步骤b)的所述夹层布置体(A，B，A')。
2.根据权利要求1所述的方法，其中所述Z-取向芯层(B)通过如下而提供：将所述起绒材料的片材多重折叠成相互平行且相邻的片材部分通过第一或第二折叠边缘成对连接的连续折叠布置体，从而产生所述Z-取向芯层，所述第一或第二折叠边缘分别沿着所述连续折叠布置体的第一面或第二面定位，所述Z-取向芯层具有暴露的第一和第二面以将表面层(A)和(A')施加到其以形成用于后续工艺步骤b)的所述夹层布置体(A，B，A')。
3.根据权利要求2所述的方法，其中所述多重折叠作为如下的连续过程进行：在该连续过程中，所述起绒材料的片材沿着加工方向(X)以第一速度v1供应，并且随后减慢至比所述第一速度v1慢的第二速度v2，从而导致所述多重折叠。
4.根据权利要求2或3所述的方法，其中所述芯层(B)包含堆叠的多个所述起绒材料的连续折叠的布置体。
5.根据权利要求2或3所述的方法，其中所述芯层(B)进一步包含至少一个所述起绒材料的未折叠层。
6.根据权利要求1至3中的一项所述的方法，其中所述增强纤维选自玻璃纤维、碳纤维、芳族聚酰胺纤维、玄武岩纤维、天然纤维和高熔点热塑性纤维。
7.根据权利要求1至3中的一项所述的方法，其中所述所述起绒热塑性材料和所述表皮热塑性材料独立地选自PP、PEI、PES、PSU、PPSU、PPA、PPO、PEEK、PPS、PA、PEAK、PEKK和PC。
8.根据权利要求1至3中的一项所述的方法，其中至少一个表皮层(A，A')包含增强片材，所述增强片材由织造织物、非卷曲织物或单向纤维布置体组成。
9.根据权利要求1至3中的一项所述的方法，其中在工艺步骤b)之前提供的芯层(B)具有50至10'000g/m2的面积重量。
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